Komatsu WA65, WA70, WA80, WA90, WA100M Wheel Loaders Repair Service Manual

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Price: US$ 59.00

Complete service repair manual with Electrical Wiring Diagrams for Komatsu WA65, WA70, WA80, WA90, WA100M Wheel Loaders, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu WA65, WA70, WA80, WA90, WA100M Wheel Loaders workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEAM04150103 - Wheel Loader WA70-1 Operation & Maintenance Manual.pdf
VEAM260200 - Wheel Loader WA80-5 Operation & Maintenance Manual.pdf
VEAM270101 - Wheel Loader WA90-5 Operation & Maintenance Manual.pdf
VEAM280201 - Wheel Loader WA100M-5 Operation & Maintenance Manual.pdf
VEAM320100 - Wheel Loader WA70-5 Operation & Maintenance Manual.pdf
VEAM320200 - Wheel Loader WA70-5 Operation & Maintenance Manual.pdf
VEAM550102 - Wheel Loader WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6 Operation & Maintenance Manual.pdf
VFAM260100 - Chargeuse sur Roues WA80-5 Instructions de Service et de Maintenance.pdf
VFAM550102 - Chargeuse sur Roues WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6 Instructions de Service et de Maintenance.pdf
VEAM970500 - Wheel Loader WA90-3 Operation & Maintenance Manual.pdf
SEBM04150104 - Wheel Loader WA70-1 Shop Manual.pdf
VEBM250100 - Wheel Loader WA65-5, WA70-5, WA80-5 Shop Manual.pdf
VEBM270100 - Wheel Loader WA90-5, WA100M-5 Shop Manual.pdf
VEBM550101 - Wheel Loader WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6 Shop Manual.pdf

PRODUCT DETAILS:
Total Pages: 4,012 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
SEAM04150103 - Wheel Loader WA70-1 Operation & Maintenance Manual...2
  COVER...2
  FOREWORD...3
  BREAKING IN YOUR NEW MACHINE...4
  CONTENTS...5
  GENERAL LOCATIONS AND SPECIFICATIONS...6
  INSTRUMENTS AND CONTROLS...7
  CHECK BEFORE STARTING...22
  OPERATING YOUR MACHINE...26
  ADJUSTMENT OF WORK EQUIPMENT...35
  HANDLING THE TIRES...37
  TOWING...40
  COLD WEATHER OPERATION...41
  PERIODICAL MAINTENANCE...46
    PERIODICAL REPLACEMENT OF SAFETY PARTS...47
    MAINTENANCE TABLE...48
    OIL FILLER AND LEVEL GAUGE POSITIONS...51
    EVERY 50 HOURS SERVICE...52
    EVERY 100 HOURS SERVICE...53
    EVERY 250 HOURS SERVICE...55
    EVERY 500 HOURS SERVICE...61
    EVERY 1000 HOURS SERVICE...64
    EVERY 2000 HOURS SERVICE...69
    EVERY 4000 HOURS SERVICE...71
    WHEN REQUIRED...72
  ADJUSTMENT...79
  TROUBLE SHOOTING GUIDE...81
  SERVICE METER...85
  MACHINE AND ENGINE SERIAL NUMBERS...86
  FUEL,COOLANT AND LUBRICANTS...87
  SAFETY AND OPERATION...89
    CONTENTS...90
    SAFETY HINTS...91
    PRECAUTIONS FOR MAINTENANCE...97
    BUCKET OPERATION...101
    LOCKING CAP...105
    HANDLING OF BATTERY...106
    TRANSPORTATION...109
    STORAGE...110
    COOLANT AND LUBRICANTS...112
SEBM04150104 - Wheel Loader WA70-1 Shop Manual...114
  COVER...114
  CONTENTS...115
  10 ENGINE...126
    12 TESTING AND ADJUSTING...126
      STANDARD VALUE TABLE...127
      TOOL LIST FOR TESTING AND ADJUSTING...128
      ADJUSTING VALVE CLEARANCE...129
      MEASURING COMPRESSION PRESSURE...130
      TESTING AND ADJUSTING FUEL INJECTION TIMING...131
      ADJUSTING FUEL INJECTION TIMING...132
      TESTING AND ADJUSTING FAN BELT TENSION...133
      TESTING AND ADJUSTING FAN BELT TENSION...133
      ADJUSTING OF FUEL CUT SOLENOID...134
      MEASURING OPERATING FORCE AND OPERATING ANGLE OF ACCELERATOR PEDAL...135
    13 DISASSEMBLY AND ASSEMBLY...138
      STARTING MOTOR...139
        REMOVAL...139
        INSTALLATION...139
      ALTERNATOR...140
        REMOVAL...140
        INSTALLATION...140
      FUEL INJECTION PUMP...141
        REMOVAL...141
        INSTALLATION...143
      NOZZLE HOLDER...146
        REMOVAL...146
        INSTALLATION...146
      WATER PUMP...147
        REMOVAL...147
        INSTALLATION...148
      CYLINDER HEAD...149
        REMOVAL...149
        INSTALLATION...153
      RADIATOR...157
        REMOVAL...157
        INSTALLATION...159
      ENGINE...162
        REMOVAL...162
        INSTALLATION...168
      FUEL TANK...174
        REMOVAL...174
        INSTALLATION...175
  20 POWER TRAIN...176
    21 STRUCTURE AND FUNCTION...176
      GENERAL...177
      HYDRAULIC CIRCUIT FOR POWER TRAIN...179
        HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN...180
      TORQUE CONVERTER AND TRANSMISSION PIPING...182
      TORQUE CONVERTER OIL FILTER...184
      TORQUE CONVERTER...185
        TORQUE CONVERTER OIL OUTLET VALVE...187
      TORQFLOW TRANSMISSION...188
      TRANSMISSION CONTROL VALVE...195
        MAIN REGULATOR VALVE...199
        QUICK RETURN VALVE AND ACCUMULATOR...200
        POWER MODULATING FUNCTION...202
        ACTION OF THE CLUTCH CUT-OFF VALVE...206
        ACCUMULATOR VALVE...208
        FORWARD 1ST...209
      TRANSMISSION CONTROL LINKAGE...211
      DRIVE SHAFT...213
      AXLE...214
      DIFFERENTIAL...216
      FINAL DRIVE...219
      AXLE MOUNT...220
      TIRE AND WHEEL...224
    22 TESTING AND ADJUSTING...225
      STANDARD VALUE TABLE...226
      TOOL LIST FOR TESTING AND ADJUSTING...227
      MEASURING ENGINE STALL SPEED...228
      MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION...230
      MEASURING SHIFT LEVER...232
      MEASURING VALVE SPOOL OPERATING FORCE AND TRAVEL...233
      TROUBLESHOOTING...234
        PRECAUTIONS WHEN TROUBLESHOOTING...235
        METHOD OF READING TROUBLESHOOTING TABLE...237
        PREVENTING RECURRENCE OF TROUBLE...239
        TROUBLESHOOTING TABLE...240
          1. MACHINE DOES NOT MOVE OFF...240
          2. MACHINE SPEED IS LOW, THRUST IS WEAK, GRADEABILITY FALLS OFF...242
          3. LARGE SHOCK WHEN MOVING OFF OR CHANGING GEAR...244
          4. LARGE TIME LAG WHEN MOVING OFF OR CHANGING GEAR...245
          5. OIL TEMPERATURE IN TORQUE CONVERTER IS HIGH...246
    23 DISASSEMBLY AND ASSEMBLY...247
      TORQUE CONVERTER, TRANSMISSION...248
        REMOVAL...248
        INSTALLATION...253
      TORQUE CONVERTER...259
        DISASSEMBLY...259
        ASSEMBLY...261
      TRANSMISSION...264
        DISASSEMBLY...264
        ASSEMBLY...271
      CLUTCH PACK...280
        DISASSEMBLY...280
        ASSEMBLY...286
      TRANSMISSION VALVE...296
        REMOVAL...296
        INSTALLATION...299
      TRANSMISSION CONTROL VALVE...302
        DISASSEMBLY...302
        ASSEMBLY...306
      DRIVE SHAFT...311
        DISASSEMBLY...311
        ASSEMBLY...313
      FRONT AXLE...315
        REMOVAL...315
        INSTALLATION...317
      REAR AXLE...319
        REMOVAL...319
        INSTALLATION...322
      DIFFERENTIAL...326
        DISASSEMBLY...326
        ASSEMBLY...329
      AXLE HOUSING...341
        DISASSEMBLY...341
        ASSEMBLY...345
    24 MAINTENANCE STANDARD...354
      TRANSMISSION AND ENGINE MOUNT...355
      TORQUE CONVERTER...356
      TRANSMISSION (1/2) (SERIAL NO. 10001-11999)...357
      TRANSMISSION (2/2) (SERIAL NO. 10001-11999)...358
      TRANSMISSION CLUTCH ASSEMBLY (SERIAL NO. 10001-11999)...360
      TRANSMISSION (1/3) (SERIAL NO. 12001AND UP)...362
      TRANSMISSION (2/3) (SERIAL NO. 12001AND UP)...363
      TRANSMISSION (3/3) (SERIAL NO. 12001AND UP)...365
      TRANSMISSION CONTROL VALVE...367
      DIFFERENTIAL (1/2)...371
      DIFFERENTIAL (2/2)...375
      DRIVE SHAFT...379
      FINAL DRIVE...380
      AXLE MOUNT...382
  40 STEERING SYSTEM...384
    41 STRUCTURE AND FUNCTION...384
      HYDRAULIC CIRCUIT FOR STEERING...385
      HYDRAULIC CIRCUIT DIAGRAM FOR STEERING...387
      FLOW DIVIDER VALVE...388
      STEERING VALVE...390
      STEERING CYLINDER...399
      CENTER HINGE PIN...400
    42 TESTING AND ADJUSTING...401
      STANDARD VALUE TABLE...402
      TOOL LIST FOR TESTING AND ADJUSTING...402
      MEASURING STEERING WHEEL PLAY...403
      MEASURING OPERATING FORCE OF STEERING WHEEL...404
      MEASURING OPERATING TIME OF STEERING WHEEL...405
      MEASURING STEERING OIL PRESSURE...406
      TROUBLESHOOTING...407
        TROUBLESHOOTING TABLE...408
          1. STEERING WHEEL DOES NOT TURN...408
          2. STEERING WHEEL IS SLUGGISH...409
          3. STEERING WHEEL MOVE UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK...410
          4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING...410
          5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT...410
    43 DISASSEMBLY AND ASSEMBLY...411
      FLOW DIVIDER VALVE...412
        REMOVAL...412
        INSTALLATION...413
        DISASSEMBLY...414
        ASSEMBLY...414
      STEERING VALVE...415
        REMOVAL...415
        INSTALLATION...416
      STEERING CYLINDER...417
        REMOVAL...417
        INSTALLATION...418
        DISASSEMBLY...419
        ASSEMBLY...421
      CENTER HINGE PIN...424
        REMOVAL...424
        INSTALLATION...428
    44 MAINTENANCE STANDARD...434
      STEERING COLUMN...435
      FLOW DIVIDER VALVE...436
      STEERING CYLINDER MOUNT...437
      STEERING CYLINDER...438
      CENTER HINGE PIN...439
  50 BRAKE SYSTEM...441
    51 STRUCTURE AND FUNCTION...441
      BRAKE PIPING...442
      BRAKE MASTER CYLINDER...444
      WHEEL BRAKE...446
      PARKING BRAKE...449
        BRAKE CALIPER...451
    52 TESTING AND ADJUSTING...452
      STANDARD VALUE TABLE...453
      TOOL LIST FOR TESTING AND ADJUSTING...454
      MEASURING BRAKE PEDAL...455
      TESTING AND ADJUSTING OF BRAKE PEDAL LINKAGE...456
      TESTING BRAKE PERFORMANCE...459
      MEASURING BRAKE OIL PRESSURE...460
      MEASURING WEAR OF BRAKE DISC...461
      AIR BLEEDING FROM BRAKE CIRCUIT...462
      TESTING PARKING BRAKE PERFORMANCE...463
      CHECKING AND ADJUSTING PARKING BRAKE...464
      MEASURING CLEARANCE OF PARKING BRAKE...466
      TROUBLESHOOTING...467
        TROUBLESHOOTING TABLE...468
          1. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE...468
          2. BRAKE CANNOT BE RELEASED OR DRAGS...469
    53 DISASSEMBLY AND ASSEMBLY...470
      MASTER CYLINDER...471
        REMOVAL...471
        INSTALLATION...472
        DISASSEMBLY...473
        ASSEMBLY...474
      PARKING BRAKE...475
        REMOVAL...475
        INSTALLATION...477
      PARKING BRAKE PAD...479
        REMOVAL...479
        INSTALLATION...480
    54 MAINTENANCE STANDARD...481
      BRAKE MASTER CYLINDER...482
      WHEEL BRAKE...483
      PARKING BRAKE...485
  60 WORK EQUIPMENT SYSTEM...486
    61 STRUCTURE AND FUNCTION...486
      GENERAL...487
      HYDRAULIC CIRCUIT...490
      HYDRAULIC CIRCUIT DIAGRAM...492
      HYDRAULIC TANK...494
        OIL FILTER...496
        BREATHER...496
      MAIN CONTROL VALVE...497
        RELIEF VALVE...501
        SAFETY VALVE...502
        SUCTION VALVE...503
      WORK EQUIPMENT LEVER LINKAGE...512
      HYDRAULIC PUMP...514
      HYDRAULIC CYLINDER...515
      BUCKET LINKAGE...516
      BUCKET POSITIONER...518
    62 TESTING AND ADJUSTING...520
      STANDARD VALUE TABLE...521
      TOOL LIST FOR TESTING AND ADJUSTING...522
      MEASURING DUMP AND LIFT CONTROL LEVERS...523
      ADJUSTING DUMP AND LIFT CONTROL LEVERS...524
      MEASURING DUMP AND LIFT CONTROL VALVE SPOOL TRAVEL...527
      MEASURING HYDRAULIC PRESSURE...528
      MEASURING LIFT ARM AND BUCKET...530
      MEASURING HYDRAULIC DRIFT OF LIFT ARM AND BUCKET...531
      ADJUSTING BUCKET POSITIONER...532
      TROUBLESHOOTING...534
        TROUBLESHOOTING TABLE...535
          1. LIFT ARM DOES NOT RISE...535
          2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER...536
          3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT...537
          4. BUCKET CANNOT BE HOLD DOWN WITH LIFT ARM CYLINDER...537
          5. LIFT HAS LARGE HYDRAULIC DRIFT...537
          6. LIFT ARM MOVEMENT IS UNSTEADY DURING WORK...537
          7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "RAISE"...537
          8. BUCKET DOES NOT TILT BACK...538
          9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER...539
          10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK...540
          11. BUCKET CANNOT BE HELD DOWN BY THE BUCKET CYLINDER...540
          12. BUCKET HAS LARGE HYDRAULIC DRIFT...540
          13. BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD...540
          14. BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "TILT BACK"...540
          15. CONTROL LEVERS OF LIFT ARM AND BUCKET MOVE STIFFLY AND SLUGGISHLY...541
    63 DISASSEMBLY AND ASSEMBLY...542
      HYDRAULIC TANK...543
        REMOVAL...543
        INSTALLATION...545
      HYDRAULIC PUMP...547
        REMOVAL...547
        INSTALLATION...549
      MAIN CONTROL VALVE...552
        REMOVAL...552
        INSTALLATION...554
        DISASSEMBLY (SERIAL NO. 10001-11999)...556
        ASSEMBLY (SERIAL NO. 10001-11999)...559
        DISASSEMBLY (SERIAL NO. 12001AND UP)...562
        ASSEMBLY (SERIAL NO. 12001 AND UP)...565
      DUMP CYLINDER...568
        REMOVAL...568
        INSTALLATION...569
      LIFT CYLINDER...570
        REMOVAL...570
        INSTALLATION...571
      LIFT AND DUMP CYLINDER...572
        DISASSEMBLY...572
        ASSEMBLY...574
      WORK EQUIPMENT...577
        REMOVAL...577
        INSTALLATION...580
      COUNTERWEIGHT...583
        REMOVAL...583
        INSTALLATION...583
    64 MAINTENANCE STANDARD...584
      MAIN CONTROL VALVE...585
      HYDRAULIC PUMP...588
      LIFT CYLINDER...589
      DUMP CYLINDER...590
      BUCKET LINKAGE...591
      BUCKET POSITIONER...595
      BUCKET...596
  80 ELECTRICAL SYSTEM...597
    81 STRUCTURE AND FUNCTION...597
      CLUSTER GAUGE...598
      ELECTRIC WIRING DIAGRAM...600
      ELECTRIC WIRING CIRCUIT DIAGRAM...602
      ENGINE STARTING CIRCUIT...604
      ENGINE STOP CIRCUIT...604
      PREHEATING CIRCUIT...606
        PREHEATING WITH STARTING SWITCH...606
      PROXIMITY SWITCH...608
    83 DISASSEMBLY AND ASSEMBLY...609
      INSTRUMENT PANEL...610
        REMOVAL...610
        INSTALLATION...611
VEAM260200 - Wheel Loader WA80-5 Operation & Maintenance Manual...612
  WA80-5_VEAM260200_0410...612
    1.  Introduction...613
      1.1.  Product publications information...614
      1.2.  Foreword...616
        EU Directives...617
      1.3.  Safety information...619
      1.4.  Introduction...621
        1.4.1.  Intended use...621
        1.4.2.  Breaking-in the machine...622
      1.5.  Location of plates...623
        1.5.1.  Machine identification plate (PIN)...623
        1.5.2.  Engine name-plate...623
        1.5.3.  Axle serial no. plate...624
        1.5.4.  Transmission serial no. plate...624
        1.5.5.  ROPS/FOPS-Cab serial no. plate...624
        1.5.6.  Seat operator serial no. plate...625
        1.5.7.  Table to enter serial no. and distributor...625
      1.6.  Emission Control Warranty...626
        1.6.1.  Emission control warranty statement (Applies to Canada only)...626
      1.7.  Garantie sur le contrôle des émissions...627
        1.7.1.  Énoncé de garantie sur le contrôle des émissions ( applicable au Canada seulement)...627
      1.8.  Table of contents...628
      1.9.  Dimensions, weights and operating data...635
      1.10.  CE-conforming equipment...636
        1.10.1.  CE-conforming equipment – part 1...636
        1.10.2.  CE-conforming equipment – part 2...636
        1.10.3.  Manufacturer-supplied CE-conforming equipment...637
      1.11.  Loading and securing...640
    2.  Safety...643
      2.1.  General safety measures...644
        2.1.1.  Safety instructions...644
        2.1.2.  Safety devices...644
        2.1.3.  Emergency exit...644
        2.1.4.  Clothing and personal protection...645
        2.1.5.  Machine modifications...645
        2.1.6.  Before you leave the driver’s seat...645
        2.1.7.  Mounting and dismounting...646
        2.1.8.  Fire prevention and fire fighting...646
        2.1.9.  Protection against asbestos dust...647
        2.1.10.  Protection against injuries...647
        2.1.11.  Working at high temperatures...648
        2.1.12.  Roll-over protection system (ROPS)...648
        2.1.13.  Attachment for protection against falling objects (FOPS)...648
        2.1.14.  Attachments...649
        2.1.15.  Battery...649
      2.2.  Safety precautions during operation...650
        2.2.1.  Prior to daily starting up...650
          Workplace safety...650
          In the driver's cab...650
          Indoor operation...651
          Gas, dust, and inflammable vapours...651
          Mirrors, windows and lighting...651
        2.2.2.  Machine operation...652
          Before you start the engine...652
          Reversing...652
          Driving...653
          Driving on slopes...653
          Emergency Lowering System...654
          Working close to power lines...655
          Loading...656
          Good Vision...656
          Working on snow...656
          Height limitation...657
          Brakes...657
          Working on loose soil...657
          Working with the forklift truck attachment...657
          Parking the machine...659
        2.2.3.  Transport...660
          Loading and unloading the machine...660
          Transport...660
      2.3.  Precautions for maintenance...661
        2.3.1.  Personnel...661
        2.3.2.  Before carrying out maintenance ...661
        2.3.3.  During maintenance...668
        2.3.4.  Tyres...672
      2.4.  Safety labels on the machine...674
        2.4.1.  Positions and order numbers of information labels...674
        2.4.2.  Positions and order numbers of safety labels...675
    3.  Operation...677
      3.1.  General view...678
        3.1.1.  General view of the machine...678
        3.1.2.  Controls and indicators...679
          Overall view...679
          Switches, controls and warning lights...680
      3.2.  Description of the individual elements...681
        3.2.1.  Instrument panel...681
          Warning lights...682
          Control lamps...684
          Measuring indicators...688
        3.2.2.  Switches...690
        3.2.3.  Control levers and pedals...697
        3.2.4.  Articulated steering catch...702
        3.2.5.  Traction device...702
        3.2.6.  Socket (12 V)...703
        3.2.7.  Door unlocking system...703
        3.2.8.  Alarm horn for reverse driving – option...703
        3.2.9.  Fuses...704
        3.2.10.  Slow-blowing fuses...705
        3.2.11.  Adjusting the heater and ventilation system...706
        3.2.12.  Air-conditioning...707
      3.3.  Operation...708
        3.3.1.  Pre-start checks...708
          Visual inspection...708
          Pre-start checks...710
          Adjustments prior to machine start...715
          Adjusting the driver’s seat...715
        3.3.2.  Starting the engine...719
          Warming up the engine...720
        3.3.3.  Driving with the machine...721
          Start-up...721
        3.3.4.  Changing the driving direction...723
        3.3.5.  Turning and steering...724
        3.3.6.  Braking...725
        3.3.7.  Stopping the machine...727
        3.3.8.  Operating the work equipment...728
          Multifunctional lever...728
          Control lever for special equipment...729
          Switching lever of bucket...730
        3.3.9.  Working with the wheel loader...731
          Tyre-appropriate operation...731
          Switching on the 100 % differential lock (if equipped)...731
          Loading work...732
          Removal work...732
          Excavation work...734
          Planing...735
          Transporting...736
          Unloading...736
          Working with the forklift truck attachment...737
        3.3.10.  Precautions for special operations...739
          Permissible water depth...739
          Working on snow...739
          Dumping on steep slopes...739
          Working in the vicinity of electrical overhead lines...739
          Operation on slopes...739
          Working on loose soil...739
          If the service brake breaks down...739
          Precautionary measures when driving up or down...740
          Precautionary measures during machine travel...741
        3.3.11.  Adjusting the position of the work equipment...742
          Selecting a work unit...742
          Removing the work unit...744
          Picking up the multi-purpose bucket...745
          Removing the multi-purpose bucket...747
          Level indicator for the bucket...747
        3.3.12.  Parking the machine...748
        3.3.13.  Switching off the engine...749
        3.3.14.  Check after stopping the engine...749
        3.3.15.  Locking...749
        3.3.16.  Tyre handling...750
          Precautionary measures when handling tyres...750
          Tyre pressure...750
      3.4.  Transporting the machine...752
        3.4.1.  Securing the articulated steering...752
        3.4.2.  Lifting the machine...753
        3.4.3.  Driving the machine onto loading area of transport vehicle...754
        3.4.4.  Securing the machine during the transport...755
        3.4.5.  After transport...755
      3.5.  Cold weather operation...756
        3.5.1.  Before the cold season...756
        3.5.2.  Precautions after completion of work...757
        3.5.3.  After the cold season...757
      3.6.  Long-term storage...758
        3.6.1.  Before storage...758
        3.6.2.  During storage...758
        3.6.3.  After storage...759
    4.  Troubleshooting...761
      4.1.  Towing the machine...762
      4.2.  Starting the engine with a booster cable...766
      4.3.  For insufficient braking effect...768
        4.3.1.  Checking the service brake...768
        4.3.2.  Checking the parking brake function...768
      4.4.  Emergency steering properties...769
      4.5.  Emergency lowering...769
      4.6.  Other troubles...770
        4.6.1.  Electrical system...770
        4.6.2.  Engine...771
        4.6.3.  Hydraulic system...774
        4.6.4.  Brakes...776
        4.6.5.  Steering...776
        4.6.6.  Axles...777
        4.6.7.  Driver's cab...777
    5.  Maintenance...779
      5.1.  Maintenance guide...780
        5.1.1.  Guidelines...780
      5.2.  Maintenance basics...787
        5.2.1.  Oil, fuel and coolant specifications...787
          Oil...787
          Fuel...788
          Coolant...789
          Grease...789
          Storing oil and fuel...790
          Filters...790
          Biodegradable hydraulic oil and  lubricants...790
        5.2.2.  Specifications of the electrical system...791
        5.2.3.  Wearing parts list...792
      5.3.  Lubricants, fuels and filling capacities...793
        5.3.1.  Lubrication chart...794
      5.4.  Tools and standard tightening torques (bolts, nuts)...795
        5.4.1.  Introduction of recommended tools...795
        5.4.2.  Torque list...796
      5.5.  Periodical replacement of safety-critical parts...798
      5.6.  Maintenance schedule chart...799
      5.7.  Service procedure...801
        5.7.1.  Pre-start checklist...801
          Cooling system – checking the coolant level, topping up coolant...801
          Cleaning the radiator segments...802
          V-Belt, checking the condition...802
          Engine, checking the oil level, topping up oil...802
          Checking the fuel level – refuelling...804
          Water separator at the fuel filter – Draining water and dirt sediments...805
          Hand pump - Checking the oil level...805
          Checking the controls...806
          Checking the electrical connections...806
          Heater/air conditioning – checking rate of air flow...807
          Miscellaneous tests before starting work...807
        5.7.2.  Maintenance upon demand...808
          Checking the air-conditioning system...808
          Checking the window washing-fluid level, adding fluid...809
          Re-charging a built-in battery...810
        5.7.3.  Maintenance after the first 50 operating hours...811
          Hydraulic system, replacing the filter insert...811
          Checking and tightening the wheel nuts...812
        5.7.4.  Maintenance after the first 250 operating hours...813
          Front and rear axle – oil change...813
          Transfer box gearing – changing oil...814
          Checking and adjusting the valve clearance...814
        5.7.5.  Maintenance every 10 operating hours...815
          Lubrication, articulated steering...815
        5.7.6.  Maintenance every 50 operating hours...816
          Checking the service brake and oil level, refilling oil...816
          Battery – checking the acid level...817
          Lubrication, work unit...818
        5.7.7.  Maintenance every 250 operating hours...819
          V-Belt, generator – checking and adjusting the tension...819
          Air filter, removing and re-installing the filter insert, checking and cleaning the filter insert...820
          Lubrication, steering cylinder...823
          Lubrication, self-aligning bearings of rear axle...824
        5.7.8.  Maintenance every 500 operating hours...825
          Engine – changing oil...825
          Replacing the oil filter cartridge...826
          Changing the fuel filter element...827
          Bleeding the fuel system...828
          Bleeding the low pressure side:...828
          Bleeding the high pressure side:...828
          Air filter, replacing the filter insert, replacing the safety filter...829
          Heater/air conditioning – cleaning/replacing filter fleece...830
          Cleaning the condenser of air conditioning...831
          E.C.S.S.-pressure accumulator (Option) - checking gas pressure...831
          Front and rear axle – checking the oil level...832
          Transfer box gearing – checking the oil level...833
        5.7.9.  Maintenance every 1000 operating hours...834
          V-Belt, generator – checking and adjusting the tension...834
          Service Brake - Checking and adjusting oil...834
          Checking and adjusting system pressures...834
          Have the system pressures checked and adjusted at an authorised Komatsu garage...834
          Hydraulics – Exchanging the venting filters...835
          Hydraulic system, replacing the filter insert...836
        5.7.10.  Maintenance every 1500 operating hours...837
          Front and rear axle – oil change...837
          Transfer box gearing – changing oil...838
        5.7.11.  Maintenance every 2000 operating hours...839
          Cooling system – exchanging coolant and cleaning the system...839
          Checking and adjusting the valve clearance...841
          Hydraulic system, oil change...842
          Ventilating the hydraulic oil tank...843
          Checking the fuel pump...844
          Checking the fuel and coolant tubes, replacing the tubes (if required)...844
          Checking the water pump...844
        5.7.12.  Maintenance every 4000 operating hours...845
          Lubrication, universal joint...845
    6.  Technical data...847
      6.1.  Technical data...848
      6.2.  Noise emission levels...849
      6.3.  Vibration level...849
      6.4.  Limit values for slopes...849
    7.  Special equipment and attachments...851
      7.1.  E.C.S.S...852
        7.1.1.  Structure and functioning principle of the E.C.S.S...852
        7.1.2.  Precautionary measures for switching on the E.C.S.S...852
        7.1.3.  Operating the E.C.S.S...853
          Switching ON the E.C.S.S...853
          Switching OFF the E.C.S.S...853
        7.1.4.  Precautions when handling the accumulator...854
    8.  Index...855
    9.  Notes...861
VEAM270101 - Wheel Loader WA90-5 Operation & Maintenance Manual...867
  1. Introduction...868
    1.1. Foreword...869
      EU Directives...870
    1.2. Safety information...872
    1.3. Introduction...874
      1.3.1. Intended use...874
      1.3.2. Breaking-in the machine...875
    1.4. Location of plates...876
      1.4.1. Machine identification plate...876
      1.4.2. Engine name-plate...876
      1.4.3. Axle serial no. plate...877
      1.4.4. Transmission serial no. plate...877
      1.4.5. ROPS/FOPS-Cab serial no. plate...877
      1.4.6. Operator’s seat serial no. plate...878
      1.4.7. Table to enter serial no. and distributor...878
    1.5. Table of contents...879
    1.6. Dimensions, weights and operating data...886
    1.7. CE-conforming equipment...887
      1.7.1. CE-conforming equipment - part 1...887
      1.7.2. CE-conforming equipment - part 2...888
      1.7.3. Manufacturer-supplied CE-conforming equipment...889
    1.8. Loading and securing...892
  2. Safety...894
    2.1. General safety measures...895
      2.1.1. Safety instructions...895
      2.1.2. Safety devices...895
      2.1.3. Emergency exit...895
      2.1.4. Clothing and personal protection...896
      2.1.5. Machine modifications...896
      2.1.6. Before you leave the driver’s seat...896
      2.1.7. Mounting and dismounting...897
      2.1.8. Fire prevention and fire fighting...897
      2.1.9. Protection against asbestos dust...898
      2.1.10. Protection against injuries...898
      2.1.11. Working at high temperatures...899
      2.1.12. Roll-over protection system (ROPS)...899
      2.1.13. Attachment for protection against falling objects (FOPS)...899
      2.1.14. Attachments...900
      2.1.15. Battery...900
    2.2. Safety precautions during operation...901
      2.2.1. Prior to daily starting up...901
        Workplace safety...901
        In the driver's cab...901
        Indoor operation...902
        Gas, dust, and inflammable vapours...902
        Mirrors, windows and lighting...902
      2.2.2. Machine operation...903
        Before you start the engine...903
        Reversing...903
        Driving...904
        Driving on slopes...904
        Emergency Lowering System...905
        Working close to power lines...906
        Loading...907
        Good Vision...907
        Working on snow...907
        Height limitation...908
        Brakes...908
        Working on loose soil...908
        Working with the forklift truck attachment...908
        Parking the machine...910
      2.2.3. Transport...911
        Loading and unloading the machine...911
        Transport...911
    2.3. Precautions for maintenance...912
      2.3.1. Personnel...912
      2.3.2. Before carrying out maintenance...912
      2.3.3. During maintenance...915
      2.3.4. Tyres...919
    2.4. Safety labels on the machine...921
      2.4.1. Positions and order numbers of safety labels...921
  3. Operation...924
    3.1. General view...925
      3.1.1. General view of the machine...925
      3.1.2. Controls and indicators...926
        Overall view...926
        Switches, controls and warning lights...927
    3.2. Description of the individual elements...928
      3.2.1. Instrument panel...928
        Warning lights...929
        Control lamps...931
        Measuring indicators...936
      3.2.2. Switches...938
      3.2.3. Control levers and pedals...946
      3.2.4. Articulated steering locking...951
      3.2.5. Traction device...951
      3.2.6. Socket (12 V)...952
      3.2.7. Door unlocking system...952
      3.2.8. Alarm horn for reverse driving - option...952
      3.2.9. Fuses...953
      3.2.10. Slow-blowing fuses...954
      3.2.11. Adjusting the heater and ventilation system...955
      3.2.12. Air-conditioning...956
    3.3. Operation...957
      3.3.1. Pre-start checks...957
        Visual inspection...957
        Pre-start checks...959
        Adjustments prior to machine start...964
        Adjusting the driver’s seat...964
      3.3.2. Starting the engine...968
        Warming up the engine...969
      3.3.3. Driving with the machine...970
        Start-up...970
        Limiting the maximum speed...971
      3.3.4. Changing the driving direction...973
      3.3.5. Turning and steering...974
      3.3.6. Braking...975
      3.3.7. Stopping the machine...977
      3.3.8. Operating the work equipment...978
        Multifunctional lever...978
        Control lever for special equipment...979
        Switching lever of bucket...980
      3.3.9. Working with the wheel loader...981
        Tyre-appropriate operation...981
        Switching on the 100 % differential lock (if equipped)...981
        Loading work...982
        Removal work...982
        Excavation work...984
        Planing...985
        Transporting...986
        Unloading...986
        Working with the forklift truck attachment...987
      3.3.10. Precautions for special operations...989
        Permissible water depth...989
        Working on snow...989
        Dumping on steep slopes...989
        Working in the vicinity of electrical overhead lines...989
        Operation on slopes...989
        Working on loose soil...989
        If the service brake breaks down...989
        Precautionary measures when driving up or down...990
        Precautionary measures during machine travel...991
      3.3.11. Adjusting the position of the work equipment...992
        Selecting a work unit...992
        Removing the work unit...994
        Picking up the multi-purpose bucket...995
        Removing the multi-purpose bucket...997
        Level indicator for the bucket...997
      3.3.12. Parking the machine...998
      3.3.13. Switching off the engine...999
      3.3.14. Check after stopping the engine...999
      3.3.15. Locking...999
      3.3.16. Tyre handling...1000
        Precautionary measures when handling tyres...1000
        Tyre pressure...1000
    3.4. Transporting the machine...1002
      3.4.1. Securing the articulated steering...1002
      3.4.2. Lifting the machine...1003
      3.4.3. Driving the machine onto loading area of transport vehicle...1004
      3.4.4. Securing the machine during the transport...1005
      3.4.5. After transport...1005
    3.5. Cold weather operation...1006
      3.5.1. Before the cold season...1006
      3.5.2. Precautions after completion of work...1007
      3.5.3. After the cold season...1007
    3.6. Long-term storage...1008
      3.6.1. Before storage...1008
      3.6.2. During storage...1008
      3.6.3. After storage...1009
  4. Troubleshooting...1010
    4.1. Towing the machine...1011
    4.2. Starting the engine with a booster cable...1015
    4.3. For insufficient braking effect...1017
      4.3.1. Checking the service brake...1017
      4.3.2. Checking the parking brake function...1017
    4.4. Emergency steering properties...1018
    4.5. Emergency lowering...1018
    4.6. Other troubles...1019
      4.6.1. Electrical system...1019
      4.6.2. Engine...1020
      4.6.3. Hydraulic system...1023
      4.6.4. Brakes...1025
      4.6.5. Steering...1025
      4.6.6. Axles...1026
      4.6.7. Driver's cab...1026
  5. Maintenance...1028
    5.1. Maintenance guide...1029
    5.2. Maintenance basics...1039
      5.2.1. Oil, fuel and coolant specifications...1039
        Oil...1039
        Fuel...1040
        Coolant...1041
        Grease...1041
        Storing oil and fuel...1042
        Filters...1042
        Biodegradable hydraulic oil and lubricants...1042
      5.2.2. Specifications of the electrical system...1043
      5.2.3. Wearing parts list...1044
    5.3. Lubricants, fuels and filling capacities...1045
    5.4. Tools...1046
      5.4.1. Introduction of recommended tools...1046
    5.5. Periodical replacement of safety-critical parts...1047
    5.6. Maintenance schedule chart...1048
    5.7. Service procedure...1050
      5.7.1. Pre-start checklist...1050
        Cooling system - checking the coolant level, topping up coolant...1050
        Cleaning the radiator segments...1051
        V-Belt, checking the condition...1051
        Engine, checking the oil level, topping up oil...1052
        Checking the fuel level - refuelling...1054
        Additional water separator (optional)...1055
        Water separator at the fuel filter - Draining water and dirt sediments...1055
        Checking the controls...1056
        Checking the electrical connections...1056
        Heater/air conditioning - checking rate of air flow...1057
        Miscellaneous tests before starting work...1057
      5.7.2. Maintenance upon demand...1058
        Checking the air-conditioning system...1058
        Checking the window washing-fluid level, adding fluid...1059
        Re-charging a built-in battery...1060
      5.7.3. Maintenance after the first 50 operating hours...1061
        Hydraulic system, replacing the filter insert...1061
        Checking and tightening the wheel nuts...1062
      5.7.4. Maintenance after the first 250 operating hours...1063
        Front and rear axle - oil change...1063
        Transfer box - changing oil...1064
        Checking and adjusting the valve clearance...1065
      5.7.5. Maintenance every 10 operating hours...1065
        Lubrication of articulated steering...1065
      5.7.6. Maintenance every 50 operating hours...1066
        Battery - checking the acid level...1066
        Lubrication of work unit...1067
      5.7.7. Maintenance every 250 operating hours...1068
        Service brake - Checking the brake pads...1068
        V-Belt, generator - checking and adjusting the tension...1068
        Air filter, removing and re-installing the filter insert, checking and cleaning the filter insert...1070
        Lubrication, steering cylinder...1073
        Lubrication, self-aligning bearings of rear axle...1074
        Checking and tightening the wheel nuts...1075
      5.7.8. Maintenance every 500 operating hours...1076
        Hand pump - Checking the oil level...1076
        Service brake - Checking the brake pads and brake discs, checking the oil level...1076
        Engine - changing oil...1078
        Replacing the oil filter cartridge...1079
        Changing the fuel filter element...1080
        Bleeding the fuel system...1081
        Bleeding the low pressure side:...1081
        Bleeding the high pressure side:...1081
        Air filter, replacing the filter insert, replacing the safety filter...1082
        Heater/air conditioning - cleaning/replacing filter fleece...1083
        Multi-functional lever accumulator - checking gas pressure...1084
        E.C.S.S.-pressure accumulator (Option) - checking gas pressure...1084
        Front and rear axle - checking the oil level...1085
        Transfer box - checking and refilling oil...1086
      5.7.9. Maintenance every 1000 operating hours...1087
        V-Belt, generator - checking and adjusting the tension...1087
        Service Brake - Checking and refilling oil...1087
        Checking and adjusting system pressures...1087
        Hydraulic - Exchanging the venting filter...1088
        Hydraulic system, replacing the filter insert...1089
      5.7.10. Maintenance every 1500 operating hours...1090
        Front and rear axle - changing oil...1090
        Transfer box - changing oil...1091
      5.7.11. Maintenance every 2000 operating hours...1092
        Cooling system - exchanging coolant and cleaning the system...1092
        Checking and adjusting the valve clearance...1094
        Hydraulic system - changing oil...1095
        Ventilating the hydraulic oil tank...1096
        Checking the fuel pump...1097
        Checking the fuel and coolant tubes, replacing the tubes (if required)...1097
        Checking the water pump...1097
      5.7.12. Maintenance every 4000 operating hours...1098
        Lubrication, drive shaft...1098
  6. Technical data...1100
    6.1. Technical data...1101
    6.2. Noise emission levels...1102
    6.3. Vibration levels...1102
      Operating condition...1102
      Guide to Reduce Vibration Levels on Machine...1102
    6.4. Limit values for slopes...1104
  7. Special equipment and attachments...1106
    7.1. E.C.S.S-electronics...1107
      7.1.1. Structure and functioning principle of the E.C.S.S-electronics...1107
      7.1.2. Precautionary measures for switching on the E.C.S.S-electronics...1107
      7.1.3. Operating the E.C.S.S-electronics...1108
        Switching ON the E.C.S.S.-electronics...1108
        Switching OFF the E.C.S.S-electronics...1108
      7.1.4. Precautions when handling the accumulator...1109
    7.2. Bucket position indicator...1110
  8. Index...1112
  9. Notes...1118
VEAM280201 - Wheel Loader WA100M-5 Operation & Maintenance Manual...1124
  1. Introduction...1126
    1.1. Product publications information...1127
    1.2. Foreword...1129
      EU Directives...1130
    1.3. Safety information...1132
    1.4. Introduction...1134
      1.4.1. Intended use...1134
      1.4.2. Breaking-in the machine...1135
    1.5. Location of plates...1136
      1.5.1. Machine identification plate (PIN)...1136
      1.5.2. Engine name-plate...1136
      1.5.3. Axle serial no. plate...1137
      1.5.4. Transmission serial no. plate...1137
      1.5.5. ROPS/FOPS-Cab serial no. plate...1137
      1.5.6. Seat operator serial no. plate...1138
      1.5.7. Table to enter serial no. and distributor...1138
    1.6. Emission Control Warranty...1139
      1.6.1. Emission control warranty statement (Applies to Canada only)...1139
    1.7. Garantie sur le contrôle des émissions...1140
      1.7.1. Énoncé de garantie sur le contrôle des émissions (applicable au Canada seulement)...1140
    1.8. Table of contents...1141
    1.9. Dimensions, weights and operating data...1148
    1.10. CE-conforming equipment...1149
      1.10.1. CE-conforming equipment - part 1...1149
      1.10.2. CE-conforming equipment - part 2...1150
      1.10.3. Manufacturer-supplied CE-conforming equipment...1151
    1.11. Loading and securing...1154
  2. Safety...1156
    2.1. General safety measures...1157
      2.1.1. Safety instructions...1157
      2.1.2. Safety devices...1157
      2.1.3. Emergency exit...1157
      2.1.4. Clothing and personal protection...1158
      2.1.5. Machine modifications...1158
      2.1.6. Before you leave the driver’s seat...1158
      2.1.7. Mounting and dismounting...1159
      2.1.8. Fire prevention and fire fighting...1159
      2.1.9. Protection against asbestos dust...1160
      2.1.10. Protection against injuries...1160
      2.1.11. Working at high temperatures...1161
      2.1.12. Roll-over protection system (ROPS)...1161
      2.1.13. Attachment for protection against falling objects (FOPS)...1161
      2.1.14. Attachments...1162
      2.1.15. Battery...1162
    2.2. Safety precautions during operation...1163
      2.2.1. Prior to daily starting up...1163
        Workplace safety...1163
        In the driver's cab...1163
        Indoor operation...1164
        Gas, dust, and inflammable vapours...1164
        Mirrors, windows and lighting...1164
      2.2.2. Machine operation...1165
        Before you start the engine...1165
        Reversing...1165
        Driving...1166
        Driving on slopes...1166
        Emergency Lowering System...1167
        Working close to power lines...1168
        Loading...1169
        Good Vision...1169
        Working on snow...1169
        Height limitation...1170
        Brakes...1170
        Working on loose soil...1170
        Working with the forklift truck attachment...1170
        Parking the machine...1172
      2.2.3. Transport...1173
        Loading and unloading the machine...1173
        Transport...1173
    2.3. Precautions for maintenance...1174
      2.3.1. Personnel...1174
      2.3.2. Before carrying out maintenance...1174
      2.3.3. During maintenance...1183
      2.3.4. Tyres...1187
    2.4. Safety labels on the machine...1189
      2.4.1. Positions and order numbers of information labels...1189
      2.4.2. Positions and order numbers of safety labels...1190
  3. Operation...1192
    3.1. General view...1193
      3.1.1. General view of the machine...1193
      3.1.2. Controls and indicators...1194
        Overall view...1194
        Switches, controls and warning lights...1195
    3.2. Description of the individual elements...1196
      3.2.1. Instrument panel...1196
        Warning lights...1197
        Control lamps...1199
        Measuring indicators...1204
      3.2.2. Switches...1206
      3.2.3. Control levers and pedals...1214
      3.2.4. Articulated steering catch...1219
      3.2.5. Traction device...1219
      3.2.6. Socket (12 V)...1220
      3.2.7. Door unlocking system...1220
      3.2.8. Alarm horn for reverse driving - option...1220
      3.2.9. Fuses...1221
      3.2.10. Slow-blowing fuses...1222
      3.2.11. Adjusting the heater and ventilation system...1223
      3.2.12. Air-conditioning...1224
    3.3. Operation...1225
      3.3.1. Pre-start checks...1225
        Visual inspection...1225
        Pre-start checks...1227
        Adjustments prior to machine start...1232
        Adjusting the driver’s seat...1232
      3.3.2. Starting the engine...1236
        Warming up the engine...1237
      3.3.3. Driving with the machine...1238
        Start-up...1238
        Limiting the maximum speed...1239
      3.3.4. Changing the driving direction...1241
      3.3.5. Turning and steering...1242
      3.3.6. Braking...1243
      3.3.7. Stopping the machine...1245
      3.3.8. Operating the work equipment...1246
        Multifunctional lever...1246
        Control lever for special equipment...1247
        Switching lever of bucket...1248
      3.3.9. Working with the wheel loader...1249
        Tyre-appropriate operation...1249
        Switching on the 100 % differential lock (if equipped)...1249
        Loading work...1250
        Removal work...1250
        Excavation work...1252
        Planing...1253
        Transporting...1254
        Unloading...1254
        Working with the forklift truck attachment...1255
      3.3.10. Precautions for special operations...1257
        Permissible water depth...1257
        Working on snow...1257
        Dumping on steep slopes...1257
        Working in the vicinity of electrical overhead lines...1257
        Operation on slopes...1257
        Working on loose soil...1257
        If the service brake breaks down...1257
        Precautionary measures when driving up or down...1258
        Precautionary measures during machine travel...1259
      3.3.11. Adjusting the position of the work equipment...1260
        Selecting a work unit...1260
        Removing the work unit...1262
        Picking up the multi-purpose bucket...1263
        Removing the multi-purpose bucket...1265
        Level indicator for the bucket...1265
      3.3.12. Parking the machine...1266
      3.3.13. Switching off the engine...1267
      3.3.14. Check after stopping the engine...1267
      3.3.15. Locking...1267
      3.3.16. Tyre handling...1268
        Precautionary measures when handling tyres...1268
        Tyre pressure...1268
    3.4. Transporting the machine...1270
      3.4.1. Securing the articulated steering...1270
      3.4.2. Lifting the machine...1271
      3.4.3. Driving the machine onto loading area of transport vehicle...1272
      3.4.4. Securing the machine during the transport...1273
      3.4.5. After transport...1273
    3.5. Cold weather operation...1274
      3.5.1. Before the cold season...1274
      3.5.2. Precautions after completion of work...1275
      3.5.3. After the cold season...1275
    3.6. Long-term storage...1276
      3.6.1. Before storage...1276
      3.6.2. During storage...1276
      3.6.3. After storage...1277
  4. Troubleshooting...1278
    4.1. Towing the machine...1279
    4.2. Starting the engine with a booster cable...1283
    4.3. For insufficient braking effect...1285
      4.3.1. Checking the service brake...1285
      4.3.2. Checking the parking brake function...1285
    4.4. Emergency steering properties...1286
    4.5. Emergency lowering...1286
    4.6. Other troubles...1287
      4.6.1. Electrical system...1287
      4.6.2. Engine...1288
      4.6.3. Hydraulic system...1291
      4.6.4. Brakes...1293
      4.6.5. Steering...1293
      4.6.6. Axles...1294
      4.6.7. Driver's cab...1294
  5. Maintenance...1296
    5.1. Maintenance guide...1297
      5.1.1. Guidelines...1297
    5.2. Maintenance basics...1307
      5.2.1. Oil, fuel and coolant specifications...1307
        Oil...1307
        Fuel...1308
        Coolant...1309
        Grease...1309
        Storing oil and fuel...1310
        Filters...1310
        Biodegradable hydraulic oil and lubricants...1310
      5.2.2. Specifications of the electrical system...1311
      5.2.3. Wearing parts list...1312
    5.3. Lubricants, fuels and filling capacities...1313
      5.3.1. Lubrication chart...1314
    5.4. Tools and standard tightening torques (bolts, nuts)...1315
      5.4.1. Introduction of recommended tools...1315
      5.4.2. Torque list...1316
    5.5. Periodical replacement of safety-critical parts...1318
    5.6. Maintenance schedule chart...1319
    5.7. Service procedure...1321
      5.7.1. Pre-start checklist...1321
        Cooling system - checking the coolant level, topping up coolant...1321
        Cleaning the radiator segments...1322
        V-Belt, checking the condition...1322
        Engine, checking the oil level, topping up oil...1323
        Checking the fuel level - refuelling...1325
        Water separator at the fuel filter - Draining water and dirt sediments...1326
        Checking the controls...1326
        Checking the electrical connections...1327
        Heater/air conditioning - checking rate of air flow...1327
        Miscellaneous tests before starting work...1328
      5.7.2. Maintenance upon demand...1328
        Checking the air-conditioning system...1328
        Checking the window washing-fluid level, adding fluid...1330
        Re-charging a built-in battery...1331
      5.7.3. Maintenance after the first 50 operating hours...1332
        Hydraulic system, replacing the filter insert...1332
        Checking and tightening the wheel nuts...1333
      5.7.4. Maintenance after the first 250 operating hours...1334
        Front and rear axle - oil change...1334
        Transfer box gearing - changing oil...1335
        Checking and adjusting the valve clearance...1335
      5.7.5. Maintenance every 10 operating hours...1336
        Lubrication, articulated steering...1336
      5.7.6. Maintenance every 50 operating hours...1337
        Checking the service brake and oil level, refilling oil...1337
        Battery - checking the acid level...1337
        Lubrication, work unit...1338
      5.7.7. Maintenance every 250 operating hours...1339
        Service brake - Checking the brake pads...1339
        V-Belt, generator - checking and adjusting the tension...1339
        Air filter, removing and re-installing the filter insert, checking and cleaning the filter insert...1341
        Lubrication, steering cylinder...1344
        Lubrication, self-aligning bearings of rear axle...1345
        Checking and tightening the wheel nuts...1346
      5.7.8. Maintenance every 500 operating hours...1347
        Hand pump - Checking the oil level...1347
        Service brake - Checking the brake pads and brake discs, checking the oil level...1347
        Engine - changing oil...1349
        Replacing the oil filter cartridge...1350
        Changing the fuel filter element...1351
        Bleeding the fuel system...1352
        Bleeding the low pressure side:...1352
        Bleeding the high pressure side:...1352
        Air filter, replacing the filter insert, replacing the safety filter...1353
        Heater/air conditioning - cleaning/replacing filter fleece...1354
        Cleaning the condenser of air conditioning...1355
        Multi-functional lever accumulator - checking gas pressure...1355
        E.C.S.S.-pressure accumulator (Option) - checking gas pressure...1355
        Front and rear axle - checking the oil level...1356
        Transfer box gearing - checking the oil level...1357
      5.7.9. Maintenance every 1000 operating hours...1358
        V-Belt, generator - checking and adjusting the tension...1358
        Service Brake - Checking and adjusting oil...1358
        Checking and adjusting system pressures...1358
        Have the system pressures checked and adjusted at an authorised Komatsu garage...1358
        Hydraulics - Exchanging the venting filters...1359
        Hydraulic system, replacing the filter insert...1360
      5.7.10. Maintenance every 1500 operating hours...1361
        Front and rear axle - oil change...1361
        Transfer box gearing - changing oil...1362
      5.7.11. Maintenance every 2000 operating hours...1363
        Cooling system - exchanging coolant and cleaning the system...1363
        Checking and adjusting the valve clearance...1365
        Hydraulic system, oil change...1366
        Ventilating the hydraulic oil tank...1367
        Checking the fuel pump...1368
        Checking the fuel and coolant tubes, replacing the tubes (if required)...1368
        Checking the water pump...1368
      5.7.12. Maintenance every 4000 operating hours...1369
        Lubrication, universal joint...1369
  6. Technical data...1370
    6.1. Technical data...1371
    6.2. Noise emission levels...1372
    6.3. Vibration levels...1372
    6.4. Limit values for slopes...1374
  7. Special equipment and attachments...1376
    7.1. E.C.S.S...1377
      7.1.1. Structure and functioning principle of the E.C.S.S...1377
      7.1.2. Precautionary measures for switching on the E.C.S.S...1377
      7.1.3. Operating the E.C.S.S...1378
        Switching ON the E.C.S.S...1378
        Switching OFF the E.C.S.S...1378
      7.1.4. Precautions when handling the accumulator...1379
  8. Index...1380
  9. Notes...1386
VEAM320100 - Wheel Loader WA70-5 Operation & Maintenance Manual...1392
  WA70-5_VEAM320100_English...1392
    1. Introduction...1393
      1.1. Foreword...1394
        EU Directives...1395
      1.2. Safety information...1397
      1.3. Introduction...1399
        1.3.1. Intended use...1399
        1.3.2. Breaking-in the machine...1400
      1.4. Location of plates...1401
        1.4.1. Machine identification plate...1401
        1.4.2. Engine name-plate...1401
        1.4.3. Axle serial no. plate...1402
        1.4.4. Transmission serial no. plate...1402
        1.4.5. ROPS/FOPS-Cab serial no. plate...1402
        1.4.6. Operator’s seat serial no. plate...1403
        1.4.7. Table to enter serial no. and distributor...1403
      1.5. Dimensions, weights and operating data...1411
      1.6. CE-conforming equipment...1412
        1.6.1. CE-conforming equipment – part 1...1412
        1.6.2. CE-conforming equipment – part 2...1412
        1.6.3. Manufacturer-supplied CE-conforming equipment...1413
      1.7. Loading and securing...1416
    2. Safety...1419
      2.1. General safety measures...1420
        2.1.1. Safety instructions...1420
        2.1.2. Safety devices...1420
        2.1.3. Emergency exit...1420
        2.1.4. Clothing and personal protection...1421
        2.1.5. Machine modifications...1421
        2.1.6. Before you leave the driver’s seat...1421
        2.1.7. Mounting and dismounting...1422
        2.1.8. Fire prevention and fire fighting...1422
        2.1.9. Protection against asbestos dust...1423
        2.1.10. Protection against injuries...1423
        2.1.11. Working at high temperatures...1424
        2.1.12. Roll-over protection system (ROPS)...1424
        2.1.13. Attachment for protection against falling objects (FOPS)...1424
        2.1.14. Attachments...1425
        2.1.15. Battery...1425
      2.2. Safety precautions during operation...1426
        2.2.1. Prior to daily starting up...1426
          Workplace safety...1426
          In the driver's cab...1426
          Indoor operation...1427
          Gas, dust, and inflammable vapours...1427
          Mirrors, windows and lighting...1427
        2.2.2. Machine operation...1428
          Before you start the engine...1428
          Reversing...1428
          Driving...1429
          Driving on slopes...1429
          Emergency Lowering System...1430
          Working close to power lines...1431
          Loading...1432
          Good Vision...1432
          Working on snow...1432
          Height limitation...1433
          Brakes...1433
          Working on loose soil...1433
          Working with the forklift truck attachment...1433
          Parking the machine...1436
        2.2.3. Transport...1437
          Loading and unloading the machine...1437
          Transport...1437
      2.3. Precautions for maintenance...1438
        2.3.1. Personnel...1438
        2.3.2. Before carrying out maintenance...1438
        2.3.3. During maintenance...1445
        2.3.4. Tyres...1449
      2.4. Safety labels on the machine...1451
        2.4.1. Positions and order numbers of safety labels...1451
    3. Operation...1455
      3.1. General view...1456
        3.1.1. General view of the machine...1456
        3.1.2. Controls and indicators...1457
          Overall view...1457
          Switches, controls and warning lights...1458
      3.2. Description of the individual elements...1459
        3.2.1. Instrument panel...1459
          Warning lights...1460
          Control lamps...1462
          Measuring indicators...1466
        3.2.2. Switches...1468
        3.2.3. Control levers and pedals...1475
        3.2.4. Articulated steering locking...1480
        3.2.5. Traction device...1480
        3.2.6. Socket (12 V)...1481
        3.2.7. Door unlocking system...1481
        3.2.8. Alarm horn for reverse driving – option...1481
        3.2.9. Fuses...1482
        3.2.10. Slow-blowing fuses...1483
        3.2.11. Adjusting the heater and ventilation system...1484
        3.2.12. Air-conditioning...1485
      3.3. Operation...1486
        3.3.1. Pre-start checks...1486
          Visual inspection...1486
          Pre-start checks...1488
          Adjustments prior to machine start...1493
          Adjusting the driver’s seat...1493
        3.3.2. Starting the engine...1497
          Warming up the engine...1498
        3.3.3. Driving with the machine...1499
          Start-up...1499
        3.3.4. Changing the driving direction...1501
        3.3.5. Turning and steering...1502
        3.3.6. Braking...1503
        3.3.7. Stopping the machine...1505
        3.3.8. Operating the work equipment...1506
          Multifunctional lever...1506
          Control lever for special equipment...1507
          Switching lever of bucket...1508
        3.3.9. Working with the wheel loader...1509
          Tyre-appropriate operation...1509
          Switching on the 100 % differential lock (if equipped)...1509
          Loading work...1510
          Removal work...1510
          Excavation work...1512
          Planing...1513
          Transporting...1514
          Unloading...1514
          Working with the forklift truck attachment...1515
        3.3.10. Precautions for special operations...1517
          Permissible water depth...1517
          Working on snow...1517
          Dumping on steep slopes...1517
          Working in the vicinity of electrical overhead lines...1517
          Operation on slopes...1517
          Working on loose soil...1517
          If the service brake breaks down...1517
          Precautionary measures when driving up or down...1518
          Precautionary measures during machine travel...1519
        3.3.11. Adjusting the position of the work equipment...1520
          Selecting a work unit...1520
          Removing the work unit...1522
          Picking up the multi-purpose bucket...1523
          Removing the multi-purpose bucket...1525
          Level indicator for the bucket...1525
        3.3.12. Parking the machine...1526
        3.3.13. Switching off the engine...1527
        3.3.14. Check after stopping the engine...1527
        3.3.15. Locking...1527
        3.3.16. Tyre handling...1528
          Precautionary measures when handling tyres...1528
          Tyre pressure...1528
      3.4. Transporting the machine...1530
        3.4.1. Securing the articulated steering...1530
        3.4.2. Lifting the machine...1531
        3.4.3. Driving the machine onto loading area of transport vehicle...1532
        3.4.4. Securing the machine during the transport...1533
        3.4.5. After transport...1533
      3.5. Cold weather operation...1534
        3.5.1. Before the cold season...1534
        3.5.2. Precautions after completion of work...1535
        3.5.3. After the cold season...1535
      3.6. Long-term storage...1536
        3.6.1. Before storage...1536
        3.6.2. During storage...1536
        3.6.3. After storage...1537
    4. Troubleshooting...1539
      4.1. Towing the machine...1540
      4.2. Starting the engine with a booster cable...1544
      4.3. For insufficient braking effect...1546
        4.3.1. Checking the service brake...1546
        4.3.2. Checking the parking brake function...1546
      4.4. Emergency steering properties...1547
      4.5. Emergency lowering...1547
      4.6. Other troubles...1548
        4.6.1. Electrical system...1548
        4.6.2. Engine...1549
        4.6.3. Hydraulic system...1552
        4.6.4. Brakes...1554
        4.6.5. Steering...1554
        4.6.6. Axles...1555
        4.6.7. Driver's cab...1555
    5. Maintenance...1557
      5.1. Maintenance guide...1558
      5.2. Maintenance basics...1566
        5.2.1. Oil, fuel and coolant specifications...1566
          Oil...1566
          Fuel...1567
          Coolant...1568
          Grease...1568
          Storing oil and fuel...1569
          Filters...1569
          Biodegradable hydraulic oil and lubricants...1569
        5.2.2. Specifications of the electrical system...1570
        5.2.3. Wearing parts list...1571
      5.3. Lubricants, fuels and filling capacities...1572
      5.4. Tools and standard tightening torques (bolts,nuts)...1573
        5.4.1. Introduction of recommended tools...1573
        5.4.2. Torque list...1574
      5.5. Periodical replacement of safety-critical parts...1576
      5.6. Maintenance schedule chart...1577
      5.7. Service procedure...1579
        5.7.1. Pre-start checklist...1579
          Cooling system – checking the coolant level, topping up coolant...1579
          Cleaning the radiator segments...1580
          V-Belt, checking the condition...1580
          Engine, checking the oil level, topping up oil...1580
          Checking the fuel level – refuelling...1582
          Water separator at the fuel filter – Draining water and dirt sediments...1583
          Hand pump - Checking the oil level...1583
          Checking the controls...1584
          Checking the electrical connections...1584
          Heater/air conditioning – checking rate of air flow...1585
          Miscellaneous tests before starting work...1585
        5.7.2. Maintenance upon demand...1586
          Checking the air-conditioning system...1586
          Checking the window washing-fluid level, adding fluid...1587
          Re-charging a built-in battery...1588
        5.7.3. Maintenance after the first 50 operating hours...1589
          Hydraulic system, replacing the filter insert...1589
          Checking and tightening the wheel nuts...1590
        5.7.4. Maintenance after the first 250 operating hours...1591
          Front and rear axle – oil change...1591
          Transfer box – changing oil...1592
          Checking and adjusting the valve clearance...1592
        5.7.5. Maintenance every 10 operating hours...1593
          Lubrication of articulated steering...1593
        5.7.6. Maintenance after the first 50 operating hours...1594
          Checking the service brake and oil level, refilling oil...1594
          Battery – checking the acid level...1595
          Lubrication of work unit...1596
        5.7.7. Maintenance every 250 operating hours...1597
          V-Belt, generator – checking and adjusting the tension...1597
          Air filter, removing and re-installing the filter insert, checking and cleaning the filter insert...1598
          Lubrication, steering cylinder...1601
          Lubrication, self-aligning bearings of rear axle...1602
        5.7.8. Maintenance every 500 operating hours...1603
          Engine – changing oil...1603
          Replacing the oil filter cartridge...1604
          Changing the fuel filter element...1605
          Bleeding the fuel system...1606
          Bleeding the low pressure side:...1606
          Bleeding the high pressure side:...1606
          Air filter, replacing the filter insert, replacing the safety filter...1607
          Heater/air conditioning – cleaning/replacing filter fleece...1608
          E.C.S.S.-pressure accumulator (Option) - checking gas pressure...1609
          Front and rear axle – checking the oil level...1610
          Transfer box – checking and refilling oil...1611
        5.7.9. Maintenance every 1000 operating hours...1612
          V-Belt, generator – checking and adjusting the tension...1612
          Service Brake - Checking and refilling oil...1612
          Checking and adjusting system pressures...1612
          Hydraulic – Exchanging the venting filter...1613
          Hydraulic system, replacing the filter insert...1614
        5.7.10. Maintenance every 1500 operating hours...1615
          Front and rear axle – changing oil...1615
          Transfer box – changing oil...1616
        5.7.11. Maintenance every 2000 operating hours...1617
          Cooling system – exchanging coolant and cleaning the system...1617
          Checking and adjusting the valve clearance...1619
          Hydraulic system - changing oil...1620
          Ventilating the hydraulic oil tank...1621
          Checking the fuel pump...1622
          Checking the fuel and coolant tubes, replacing the tubes (if required)...1622
          Checking the water pump...1622
        5.7.12. Maintenance every 4000 operating hours...1623
          Lubrication, drive shaft...1623
    6. Technical data...1625
      6.1. Technical data...1626
      6.2. Noise emission levels...1627
      6.3. Vibration level...1627
      6.4. Limit values for slopes...1627
    7. Special equipment and attachments...1629
      7.1. E.C.S.S-electronics...1630
        7.1.1. Structure and functioning principle of the E.C.S.S-electronics...1630
        7.1.2. Precautionary measures for switching on the E.C.S.S-electronics...1630
        7.1.3. Operating the E.C.S.S-electronics...1631
          Switching ON the E.C.S.S.electronics...1631
          Switching OFF the E.C.S.S-electronics...1631
        7.1.4. Precautions when handling the accumulator...1632
    8. Index...1633
    9. Notes...1639
VEAM320200 - Wheel Loader WA70-5 Operation & Maintenance Manual...1645
  WA70-5_VEAM320200_USA...1645
    1. Introduction...1646
      1.1. Product publications information...1647
      1.2. Foreword...1649
        EU Directives...1650
      1.3. Safety information...1652
      1.4. Introduction...1654
        1.4.1. Intended use...1654
        1.4.2. Breaking-in the machine...1655
      1.5. Location of plates...1656
        1.5.1. Machine identification plate (PIN)...1656
        1.5.2. Engine name-plate...1656
        1.5.3. Axle serial no. plate...1657
        1.5.4. Transmission serial no. plate...1657
        1.5.5. ROPS/FOPS-Cab serial no. plate...1657
        1.5.6. Seat operator serial no. plate...1658
        1.5.7. Table to enter serial no. and distributor...1658
      1.6. Emission Control Warranty...1659
        1.6.1. Emission control warranty statement (Applies to Canada only)...1659
      1.7. Garantie sur le contrôle des émissions...1660
        1.7.1. Énoncé de garantie sur le contrôle des émissions (applicable au Canada seulement)...1660
      1.8. Table of contents...1661
      1.9. Dimensions, weights and operating data...1668
      1.10. CE-conforming equipment...1669
        1.10.1. CE-conforming equipment – part 1...1669
        1.10.2. CE-conforming equipment – part 2...1669
        1.10.3. Manufacturer-supplied CE-conforming equipment...1670
      1.11. Loading and securing...1673
    2. Safety...1676
      2.1. General safety measures...1677
        2.1.1. Safety instructions...1677
        2.1.2. Safety devices...1677
        2.1.3. Emergency exit...1677
        2.1.4. Clothing and personal protection...1678
        2.1.5. Machine modifications...1678
        2.1.6. Before you leave the driver’s seat...1678
        2.1.7. Mounting and dismounting...1679
        2.1.8. Fire prevention and fire fighting...1679
        2.1.9. Protection against asbestos dust...1680
        2.1.10. Protection against injuries...1680
        2.1.11. Working at high temperatures...1681
        2.1.12. Roll-over protection system (ROPS)...1681
        2.1.13. Attachment for protection against falling objects (FOPS)...1681
        2.1.14. Attachments...1682
        2.1.15. Battery...1682
      2.2. Safety precautions during operation...1683
        2.2.1. Prior to daily starting up...1683
          Workplace safety...1683
          In the driver's cab...1683
          Indoor operation...1684
          Gas, dust, and inflammable vapours...1684
          Mirrors, windows and lighting...1684
        2.2.2. Machine operation...1685
          Before you start the engine...1685
          Reversing...1685
          Driving...1686
          Driving on slopes...1686
          Emergency Lowering System...1687
          Working close to power lines...1688
          Loading...1689
          Good Vision...1689
          Working on snow...1689
          Height limitation...1690
          Brakes...1690
          Working on loose soil...1690
          Working with the forklift truck attachment...1690
          Parking the machine...1692
        2.2.3. Transport...1693
          Loading and unloading the machine...1693
          Transport...1693
      2.3. Precautions for maintenance...1694
        2.3.1. Personnel...1694
        2.3.2. Before carrying out maintenance...1694
        2.3.3. During maintenance...1701
        2.3.4. Tyres...1705
      2.4. Safety labels on the machine...1707
        2.4.1. Positions and order numbers of information labels...1707
        2.4.2. Positions and order numbers of safety labels...1708
    3. Operation...1710
      3.1. General view...1711
        3.1.1. General view of the machine...1711
        3.1.2. Controls and indicators...1712
          Overall view...1712
          Switches, controls and warning lights...1713
      3.2. Description of the individual elements...1714
        3.2.1. Instrument panel...1714
          Warning lights...1715
          Control lamps...1717
          Measuring indicators...1721
        3.2.2. Switches...1723
        3.2.3. Control levers and pedals...1730
        3.2.4. Articulated steering catch...1735
        3.2.5. Traction device...1735
        3.2.6. Socket (12 V)...1736
        3.2.7. Door unlocking system...1736
        3.2.8. Alarm horn for reverse driving – option...1736
        3.2.9. Fuses...1737
        3.2.10. Slow-blowing fuses...1738
        3.2.11. Adjusting the heater and ventilation system...1739
        3.2.12. Air-conditioning...1740
      3.3. Operation...1741
        3.3.1. Pre-start checks...1741
          Visual inspection...1741
          Pre-start checks...1743
          Adjustments prior to machine start...1748
          Adjusting the driver’s seat...1748
        3.3.2. Starting the engine...1752
          Warming up the engine...1753
        3.3.3. Driving with the machine...1754
          Start-up...1754
        3.3.4. Changing the driving direction...1756
        3.3.5. Turning and steering...1757
        3.3.6. Braking...1758
        3.3.7. Stopping the machine...1760
        3.3.8. Operating the work equipment...1761
          Multifunctional lever...1761
          Control lever for special equipment...1762
          Switching lever of bucket...1763
        3.3.9. Working with the wheel loader...1764
          Tyre-appropriate operation...1764
          Switching on the 100 % differential lock (if equipped)...1764
          Loading work...1765
          Removal work...1765
          Excavation work...1767
          Planing...1768
          Transporting...1769
          Unloading...1769
          Working with the forklift truck attachment...1770
        3.3.10. Precautions for special operations...1772
          Permissible water depth...1772
          Working on snow...1772
          Dumping on steep slopes...1772
          Working in the vicinity of electrical overhead lines...1772
          Operation on slopes...1772
          Working on loose soil...1772
          If the service brake breaks down...1772
          Precautionary measures when driving up or down...1773
          Precautionary measures during machine travel...1774
        3.3.11. Adjusting the position of the work equipment...1775
          Selecting a work unit...1775
          Removing the work unit...1777
          Picking up the multi-purpose bucket...1778
          Removing the multi-purpose bucket...1780
          Level indicator for the bucket...1780
        3.3.12. Parking the machine...1781
        3.3.13. Switching off the engine...1782
        3.3.14. Check after stopping the engine...1782
        3.3.15. Locking...1782
        3.3.16. Tyre handling...1783
          Precautionary measures when handling tyres...1783
          Tyre pressure...1783
      3.4. Transporting the machine...1785
        3.4.1. Securing the articulated steering...1785
        3.4.2. Lifting the machine...1786
        3.4.3. Driving the machine onto loading area of transport vehicle...1787
        3.4.4. Securing the machine during the transport...1788
        3.4.5. After transport...1788
      3.5. Cold weather operation...1789
        3.5.1. Before the cold season...1789
        3.5.2. Precautions after completion of work...1790
        3.5.3. After the cold season...1790
      3.6. Long-term storage...1791
        3.6.1. Before storage...1791
        3.6.2. During storage...1791
        3.6.3. After storage...1792
    4. Troubleshooting...1794
      4.1. Towing the machine...1795
      4.2. Starting the engine with a booster cable...1799
      4.3. For insufficient braking effect...1801
        4.3.1. Checking the service brake...1801
        4.3.2. Checking the parking brake function...1801
      4.4. Emergency steering properties...1802
      4.5. Emergency lowering...1802
      4.6. Other troubles...1803
        4.6.1. Electrical system...1803
        4.6.2. Engine...1804
        4.6.3. Hydraulic system...1807
        4.6.4. Brakes...1809
        4.6.5. Steering...1809
        4.6.6. Axles...1810
        4.6.7. Driver's cab...1810
    5. Maintenance...1812
      5.1. Maintenance guide...1813
        5.1.1. Guidelines...1813
      5.2. Maintenance basics...1820
        5.2.1. Oil, fuel and coolant specifications...1820
          Oil...1820
          Fuel...1821
          Coolant...1822
          Grease...1822
          Storing oil and fuel...1823
          Filters...1823
          Biodegradable hydraulic oil and lubricants...1823
        5.2.2. Specifications of the electrical system...1824
        5.2.3. Wearing parts list...1825
      5.3. Lubricants, fuels and filling capacities...1826
        5.3.1. Lubrication chart...1827
      5.4. Tools and standard tightening torques (bolts,nuts)...1828
        5.4.1. Introduction of recommended tools...1828
        5.4.2. Torque list...1829
      5.5. Periodical replacement of safety-critical parts...1831
      5.6. Maintenance schedule chart...1832
      5.7. Service procedure...1834
        5.7.1. Pre-start checklist...1834
          Cooling system – checking the coolant level, topping up coolant...1834
          Cleaning the radiator segments...1835
          V-Belt, checking the condition...1835
          Engine, checking the oil level, topping up oil...1835
          Checking the fuel level – refuelling...1837
          Water separator at the fuel filter – Draining water and dirt sediments...1838
          Hand pump - Checking the oil level...1838
          Checking the controls...1839
          Checking the electrical connections...1839
          Heater/air conditioning – checking rate of air flow...1840
          Miscellaneous tests before starting work...1840
        5.7.2. Maintenance upon demand...1841
          Checking the air-conditioning system...1841
          Checking the window washing-fluid level, adding fluid...1842
          Re-charging a built-in battery...1843
        5.7.3. Maintenance after the first 50 operating hours...1844
          Hydraulic system, replacing the filter insert...1844
          Checking and tightening the wheel nuts...1845
        5.7.4. Maintenance after the first 250 operating hours...1846
          Front and rear axle – oil change...1846
          Transfer box gearing – changing oil...1847
          Checking and adjusting the valve clearance...1847
        5.7.5. Maintenance every 10 operating hours...1848
          Lubrication, articulated steering...1848
        5.7.6. Maintenance every 50 operating hours...1849
          Checking the service brake and oil level, refilling oil...1849
          Battery – checking the acid level...1850
          Lubrication, work unit...1851
        5.7.7. Maintenance every 250 operating hours...1852
          V-Belt, generator – checking and adjusting the tension...1852
          Air filter, removing and re-installing the filter insert, checking and cleaning the filter insert...1853
          Lubrication, steering cylinder...1856
          Lubrication, self-aligning bearings of rear axle...1857
        5.7.8. Maintenance every 500 operating hours...1858
          Engine – changing oil...1858
          Replacing the oil filter cartridge...1859
          Changing the fuel filter element...1860
          Bleeding the fuel system...1861
          Bleeding the low pressure side:...1861
          Bleeding the high pressure side:...1861
          Air filter, replacing the filter insert, replacing the safety filter...1862
          Heater/air conditioning – cleaning/replacing filter fleece...1863
          Cleaning the condenser of air conditioning...1864
          E.C.S.S.-pressure accumulator (Option) - checking gas pressure...1864
          Front and rear axle – checking the oil level...1865
          Transfer box gearing – checking the oil level...1866
        5.7.9. Maintenance every 1000 operating hours...1867
          V-Belt, generator – checking and adjusting the tension...1867
          Service Brake - Checking and adjusting oil...1867
          Checking and adjusting system pressures...1867
          Have the system pressures checked and adjusted at an authorised Komatsu garage...1867
          Hydraulics – Exchanging the venting filters...1868
          Hydraulic system, replacing the filter insert...1869
        5.7.10. Maintenance every 1500 operating hours...1870
          Front and rear axle – oil change...1870
          Transfer box gearing – changing oil...1871
        5.7.11. Maintenance every 2000 operating hours...1872
          Cooling system – exchanging coolant and cleaning the system...1872
          Checking and adjusting the valve clearance...1874
          Hydraulic system, oil change...1875
          Ventilating the hydraulic oil tank...1876
          Checking the fuel pump...1877
          Checking the fuel and coolant tubes, replacing the tubes (if required)...1877
          Checking the water pump...1877
        5.7.12. Maintenance every 4000 operating hours...1878
          Lubrication, universal joint...1878
    6. Technical data...1880
      6.1. Technical data...1881
      6.2. Noise emission levels...1882
      6.3. Vibration level...1882
      6.4. Limit values for slopes...1882
    7. Special equipment and attachments...1884
      7.1. E.C.S.S...1885
        7.1.1. Structure and functioning principle of the E.C.S.S...1885
        7.1.2. Precautionary measures for switching on the E.C.S.S...1885
        7.1.3. Operating the E.C.S.S...1886
          Switching ON the E.C.S.S...1886
          Switching OFF the E.C.S.S...1886
        7.1.4. Precautions when handling the accumulator...1887
    8. Index...1888
    9. Notes...1894
VEAM550102 - Wheel Loader WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6 Operation & Maintenance Manual...1900
  1. Foreword...1902
    1.1 Foreword...1903
      1.1.1 EU Directives...1905
    1.2 Safety information...1906
      1.2.1 Signal words...1906
      1.2.2 Safety labels...1908
    1.3 Introduction...1909
      1.3.1 Intended use...1909
    1.4 Key data of the machine...1911
      1.4.1 Product identification number (PIN)/Machine serial no. plate and position...1911
      1.4.2 Engine serial no. plate...1912
      1.4.3 Axle serial no. plate...1912
      1.4.4 Transmission serial no. plate...1912
      1.4.5 ROPS/FOPS cab serial no. plate...1913
      1.4.6 Operator's seat serial no. plate...1913
      1.4.7 Table to enter serial number and distributor...1914
      1.4.8 Declaration of conformity (for machines placed on the market as from 29th December 2009)...1915
    1.5 Emission control warranty...1916
      1.5.1 Emission control warranty statement (Applies to Canada only)...1916
    1.6 Garantie sur le contrôle des émissions...1917
      1.6.1 Énoncé de garantie sur le contrôle des émissions (applicable au Canada seulement)...1917
    1.7 Table of contents...1918
    1.8 Dimensions, weights, and operating data...1925
      1.8.1 WA65-6, WA70-6, WA80-6...1925
      1.8.2 WA90-6, WA100M-6...1927
    1.9 CE-conforming equipment...1929
      1.9.1 CE-conforming equipment - part 1...1929
      1.9.2 CE-conforming equipment - part 2...1931
      1.9.3 Manufacturer-supplied CE-conforming equipment...1932
  2. Safety...1938
    2.1 Safety labels...1939
      2.1.1 Position of the safety labels (for Europe)...1939
      2.1.2 Position of the safety labels (for USA)...1941
    2.2 General precautions...1944
    2.3 Precautions during operation...1956
      2.3.1 Starting the engine...1956
      2.3.2 Operation...1958
      2.3.3 Transport...1965
      2.3.4 Battery...1966
    2.4 Precautions for maintenance...1968
  3. Operation...1980
    3.1 General view...1981
      3.1.1 General view of the machine...1981
      3.1.2 Controls...1983
        General view...1983
      3.1.3 Machine monitor...1985
      3.1.4 Switches...1987
    3.2 Descriptions of the individual elements...1989
      3.2.1 Machine monitor...1989
        Caution lamps...1990
        Pilot lamps...1993
        Gauges...1999
      3.2.2 Switches...2001
      3.2.3 Control levers and pedals...2011
      3.2.4 Steering lock...2016
      3.2.5 Tow hitch...2016
      3.2.6 Power outlet...2017
      3.2.7 Door and window detent release...2017
      3.2.8 Back-up alarm...2017
      3.2.9 Fuses...2018
      3.2.10 Slow-blow fuses...2020
      3.2.11 Adjusting the heating and ventilation system...2021
      3.2.12 Air conditioner...2022
    3.3 Operation...2024
      3.3.1 Checks before starting...2024
        Visual checks...2024
        Checks before starting the engine...2027
        Adjustments before starting...2037
      3.3.2 Starting the engine...2041
        Ambient temperature range for operation and storage...2042
        Checks after starting the engine...2043
      3.3.3 Driving the machine...2044
        Starting...2044
        Limiting the maximum speed...2045
      3.3.4 Changing direction...2047
      3.3.5 Turning and steering...2048
      3.3.6 Braking...2049
        Engaging the parking brake...2049
        Disengaging the parking brake...2049
        Braking with the service brake...2049
        If the service brake fails...2050
        Braking on slopes...2050
      3.3.7 Stopping and parking the machine...2051
      3.3.8 Operating the work equipment...2052
        Multi-function lever...2052
      3.3.9 Return to dig...2053
      3.3.10 Working with the wheel loader...2054
        Saving the tyres...2054
        Switching on the 100 % differential lock...2055
        Loading...2056
        Digging...2056
        Excavating...2058
        Levelling...2059
        Carrying...2060
        Loading...2061
        Working with the forklift attachment...2062
      3.3.11 Operating precautions...2064
        Permissible water depth...2064
        Working on snow...2064
        Dumping on steep slopes...2064
        Working near high-voltage cables...2064
        Working on road shoulders...2064
        Working on loose ground...2064
        If the service brake fails...2064
        Precautions for driving uphill or downhill...2065
        Precautions when driving...2065
      3.3.12 Adjusting the work equipment...2066
        Selecting the work equipment...2066
        Attaching the work equipment...2066
        Removing the work equipment...2069
        Removing the multi-purpose bucket...2070
        Bucket level indicator...2070
      3.3.13 Switching off the engine...2071
      3.3.14 Checks after switching off the engine...2071
      3.3.15 Locking...2071
      3.3.16 Handling tyres...2072
        Precautions when handling tyres...2072
        Tyre pressure...2072
        Standard tyres...2073
    3.4 Transport...2074
      3.4.1 Transporting procedure...2074
        Ensure machine stability...2074
      3.4.2 Loading the machine...2074
        Loading the machine...2075
        Securing the machine...2076
        Unloading the machine...2078
      3.4.3 Lifting the machine...2079
        Lifting procedure...2082
    3.5 Operation in cold weather...2083
      3.5.1 Precautions for operation in cold weather...2083
      3.5.2 Precautions after work...2084
      3.5.3 After the cold weather period...2084
    3.6 Long-term storage...2085
      3.6.1 Before storage...2085
      3.6.2 During storage...2085
      3.6.3 After storage...2086
    3.7 Machines equipped with KOMTRAX...2087
      3.7.1 Basic precautions...2087
    3.8 Reading error codes...2089
      3.8.1 Setting the monitor...2090
  4. Troubleshooting...2092
    4.1 Towing machine...2093
    4.2 Starting the engine with booster cables...2097
    4.3 In case of insufficient brake power...2100
      4.3.1 Checking the service brake...2100
      4.3.2 Checking the parking brake...2100
    4.4 Emergency steering properties...2101
    4.5 Emergency lowering...2102
    4.6 Other troubles...2103
      4.6.1 Electrical system...2103
      4.6.2 Engine...2104
      4.6.3 Hydraulic...2107
      4.6.4 Brakes...2109
      4.6.5 Steering...2110
      4.6.6 Axles...2110
      4.6.7 Operator's cab...2110
  5. Maintenance...2112
    5.1 Maintenance guide...2113
      5.1.1 Tipping up the operator's cab...2114
      5.1.2 Tipping down the operator's cab...2116
    5.2 Basic maintenance guidelines...2121
      5.2.1 Fuel, coolant and lubricant specifications...2122
        Oil...2122
        Fuel...2123
        Coolant...2124
        Grease...2125
        Storing oil and fuel...2125
        Filters...2126
        Biodegradable hydraulic oil and lubricants...2126
      5.2.2 Outlines of the electrical system...2127
    5.3 Wear parts list...2128
      5.3.1 Wear parts list...2128
    5.4 Fuel, lubricants, and coolants; quantities...2129
      5.4.1 Lubrication table...2129
      5.4.2 Recommended brands, recommended quality for products other than KOMATSU genuine oil...2132
    5.5 Tools...2133
      5.5.1 List of required tools...2133
    5.6 Periodic replacement of safety-critical parts...2134
    5.7 Maintenance schedule...2135
    5.8 Maintenance procedure...2137
      5.8.1 Checks before starting the engine...2137
      5.8.2 Corrective maintenance...2138
        Checking the air conditioner...2138
        Checking the window washer fluid level - adding fluid...2140
        Battery - charging the built-in battery...2140
        Cleaning the air grille...2141
        Cleaning the radiator fins...2141
      5.8.3 Maintenance after the first 50 service hours...2142
        Hydraulic system - change filter insert...2142
        Wheel nuts - check and retighten...2142
        Lubrication - rear axle...2143
      5.8.4 Maintenance after the first 250 service hours...2144
        Front and rear axle - change oil...2144
        Transfer case - change oil...2144
        Valve clearance - check and adjust...2144
      5.8.5 Maintenance every 10 service hours...2145
        Lubrication - articulated steering...2145
      5.8.6 Maintenance every 50 service hours...2146
        Battery - check fluid level...2146
        Lubrication - work equipment...2147
      5.8.7 Maintenance every 250 service hours...2149
        Service brake - check brake pads...2149
        Alternator v-belt - check and adjust tension...2150
        Air cleaner - checking, cleaning, or replacing...2151
        Lubrication - steering cylinder...2154
        Lubrication - rear axle...2155
        Wheel nuts - check and retighten...2156
      5.8.8 Maintenance every 500 service hours...2157
        Manual pump - check oil level...2157
        Service brake - check brake pads and brake disc, check oil level...2158
        Engine - change engine oil...2159
        Changing the oil filter cartridge...2160
        Fuel filter - change filter cartridge...2161
        Bleeding the fuel system...2163
        Changing the filter insert of the air cleaner, changing the safety filter...2164
        Heating/air conditioner - clean/renew filter cloth, clean condenser...2165
        Checking the gas pressure in the pressure accumulator for the multi-function lever...2166
        E.C.S.S. pressure accumulator - check gas pressure...2166
        Front and rear axle - check oil level...2167
        Transfer case - check oil level, add oil...2168
      5.8.9 Maintenance every 1000 service hours...2169
        Alternator v-belt - check and adjust tension...2169
        Service brake - check, change brake fluid...2170
        System pressures - check and adjust...2170
        Hydraulic system - change venting filters...2171
        Hydraulic system - change filter insert...2172
      5.8.10 Maintenance every 1500 service hours...2173
        Front and rear axle - change oil...2173
        Transfer case - change oil...2175
      5.8.11 Maintenance every 2000 service hours...2176
        Cooling system - change coolant and clean cooling system...2176
        Valve clearance - check and adjust...2179
        Hydraulic system - change hydraulic oil...2180
        Checking the fuel pump...2182
        Fuel and coolant hoses - check, replace if required...2182
        Checking the water pump...2182
      5.8.12 Maintenance every 4000 service hours...2183
        Lubrication - cardan shaft...2183
  6. Technical data...2184
    6.1 Technical data...2185
      6.1.1 WA65-6...2185
      6.1.2 WA70-6...2185
      6.1.3 WA80-6...2186
      6.1.4 WA90-6...2186
      6.1.5 WA100M-6...2187
    6.2 Noise emission level...2188
    6.3 Vibration levels...2189
    6.4 Limit values for slopes...2191
  7. Special equipment, attachments...2192
    7.1 E.C.S.S...2193
      7.1.1 Design and functional principle of the E.C.S.S...2193
      7.1.2 Precautions when switching on the E.C.S.S...2193
      7.1.3 Operating the E.C.S.S...2194
        Switching on the E.C.S.S...2194
        Switching off the E.C.S.S...2194
      7.1.4 Precautions when handling the pressure accumulator...2194
    7.2 Bucket position indicator...2195
    7.3 Central lubrication system...2196
      7.3.1 Operating the central lubrication system...2196
      7.3.2 Display and operating unit...2196
        LED display...2197
        Buttons...2197
      7.3.3 Changing the lubrication intervals and duration...2198
    7.4 Multi-function lever with 3rd control circuit...2199
      7.4.1 Operating the switch...2199
  8. Index...2202
    8.1 Index...2203
  9. Notes...2208
VEAM970500 - Wheel Loader WA90-3 Operation & Maintenance Manual...2214
  COVER...2214
  Contents...2216
  Information on these Operating Instructions...2220
    Why You Should Read these Operating Instructions...2222
    Notes on Safety Regulations...2223
    CE-Conforming Equipment...2227
  Loading and Transporting the Machine...2232
    Loading and Transporting the Machine...2234
    Dimensions, Weights, and Operating Values...2237
    Technical Data...2238
  Safety...2240
    General Safety Measures...2241
    Before You Start the Engine...2247
    Machine Operation...2249
    Transport...2255
    Safety Measures During Maintenance...2256
    Labeling...2263
  Controls and Indicators...2266
    Overall View of the Machine...2268
    Controls and Indicators...2269
      Instrument Panel...2270
      Warning Lights...2271
      Control Lamps...2273
      Measuring Indicators...2276
      Switches...2278
      Control Levers, Pedals...2284
  Operation...2290
    Running in the Machine...2292
    Preparing the Machine Start...2293
    Adjustments Prior to Machine Start...2295
    Starting and Switching Off the Engine...2300
    Driving...2302
    Operating the Machine...2309
  Troubleshooting...2322
    Troubleshooting...2324
      Electrical System...2325
      Engine...2326
      Hydraulic System...2329
      Brakes...2331
      Axles...2332
      Driver's cab...2332
  Maintenance...2340
    Maintenance Basics...2342
    Maintenance Schedule...2360
    Maintenance Prior to Start...2362
    Maintenance upon Demand...2366
    Maintenance Every 10 Operating Hours...2367
    Maintenance After the First 50 Operating Hours...2368
    Maintenance Every 50 Operating Hours...2374
    Maintenance Every 100 Operating Hours...2379
    Maintenance Every 250 Operating Hours...2380
    Maintenance Every 500 Operating Hours...2385
    Maintenance Every 1000 Operating Hours...2392
    Maintenance Every 2000 Operating Hours...2395
  Technical Data...2398
    Technical Data...2399
  Special Equipment and Attachments...2402
    ALS-Electronics...2404
  Index...2406
VEBM250100 - Wheel Loader WA65-5, WA70-5, WA80-5 Shop Manual...2412
  VEBM250100_WA65-5_WA80-5_Shop_Manual...2412
  SAFETY...2414
    Safety notice...2416
      Preparations for work...2417
      Tipping up the driver's cab...2417
      Tipping down the driver's cab...2420
      Precautions during work...2421
    Foreword...2424
    How to read the shop manual...2425
      Volumes...2425
      Distribution and updating...2425
      Filing method...2425
      Symbols...2426
    Hoisting instructions...2427
      Wire ropes...2427
  GENERAL...2430
    Dimensions, weights and operating data WA65-5...2432
    Specifications WA65-5...2433
    Weight table WA65-5...2434
    Dimensions, weights and operating data WA70-5...2435
    Specifications WA70-5...2436
    Weight table WA70-5...2437
    Dimensions, weights and operating data WA80-5...2438
    Specifications WA80-5...2439
    Weight table WA80-5...2440
    Lubricants and operating mediums: WA65-5/ WA70-5...2441
    Lubricants and operating mediums: WA80-5...2442
    Basic procedures of maintenance...2443
      Oil...2443
      Fuel...2443
      Coolant...2444
      Grease...2444
      Storing oil and fuel...2444
      Filters...2445
      Biodegradable hydraulic oils and lubricants...2445
      Outline of electric system...2445
    Torque list – screws and nuts...2446
  STRUCTURE AND FUNCTION...2448
    Powertrain...2450
    Closed circuit...2451
    Hydraulic drive system 20Km/h...2452
    Hydraulic drive system 30Km/h...2453
    Variable displacement pump...2454
      Regulating valve...2457
      Charge pressure limiting valve...2457
      Control cylinder...2458
      4/3 Way valve with direction control solenoids...2458
      Pressure cut-off valve...2459
      Safety-/charge valve...2459
      Towing...2460
    Variable displacement motor...2461
    Drive shaft...2463
    Axle mounting – front axle...2464
    Axle mounting – rear axle...2464
    WA65-5 / WA70-5: Front axle...2465
      With outer disc brake as service brake and parking brake...2465
    WA80-5: Front axle...2466
      With inner disc brake as service brake and outer disc brake as parking brake...2466
    Rear axle with transfer box...2467
    Transfer box TB172...2468
    Limited slip differential (locking value 25%)...2469
    Locking differential (locking value 100%)...2471
    Wheel hub, front and rear axle...2473
    WA65-5 / WA70-5: Service and parking brake, front axle...2474
    WA80-5: Service brake, front axle...2476
    WA80-5: Parking brake, front axle...2477
    Sevice and parking brake circuit...2478
    WA65-5 / WA70-5: Service brake assembly...2479
    WA80-5: Service brake assembly...2480
    Inch-brake Valve...2481
    Steering articulation joint...2482
    Steering system...2483
      Hydraulic circuit diagram of steering system...2483
      Priority valve...2484
      Orbit-roll-valve...2485
      Steering relief valve...2486
    Work equipment hydraulic WA65/WA70-5...2487
      Travel, steering and work hydraulics...2487
    Work equipment hydraulic WA80-5...2489
      Travel, steering and work hydraulics...2489
    PPC-Valve...2491
      Operation of PPC-valve...2492
      Servo pressure regulating valve...2493
      Emergency Lowering System...2493
    Main control valve...2495
    WA65-5 / WA70-5: Lift cylinder...2497
    WA80-5: Lift cylinder...2498
    Dump cylinder...2499
    Steering cylinder...2500
    Lifting frame with quick-coupler...2501
    Quick-coupler...2502
    Monitor display...2503
    Sensors...2504
      Engine oil pressure sensor...2504
      Fuel level sensor...2505
      Engine coolant temperature sensor...2506
      Brake oil reservoir sensor...2507
    Ribbon heater...2508
    Engine stop / start / preheating circuit...2509
    Electrical fuses and relays...2511
      Fuses...2511
      Relays...2512
      Engine room...2513
    Electrical diagrams...2514
      Wiring diagram 1/5 - foldout 90-9...2514
      Wiring diagram 2/5 - foldout 90-11...2514
      Wiring diagram 3/5 - foldout 90-13...2514
      Wiring diagram 4/5 - foldout 90-15...2514
      Wiring diagram 5/5 - foldout 90-17...2514
      Speed control - foldout 90-19...2514
      Immobilizer - foldout 90-21...2514
    Air conditioner (option)...2515
      Introduction...2515
      Function...2516
      The coolant circuit...2516
      The condenser...2518
      The vaporizer...2519
      The filter dryer...2520
      Installation of air conditioner...2522
      Safety when handling coolants...2523
      Operating the air conditioner...2525
      Maintenance of the air conditioner...2526
      Regular maintenance...2527
      Instructions for filling...2529
      Exchange of magnetic clutch...2532
      Exchange of compressor...2533
      Troubleshooting...2535
  TESTING AND ADJUSTING...2540
    Standard value table for engine - WA65-5 / WA70-5 / WA80-5...2542
    Standard value table for chassis – WA65-5...2543
    Standard value table for chassis – WA70-5...2545
    Standard value table for chassis – WA80-5...2547
    Standard value table for electrical parts...2549
    Test certificate – WA65-5...2550
    Test certificate – WA70-5...2551
    Test certificate – WA80-5...2552
    Valve lash clearance...2553
    Engine compression test...2555
    Injection nozzle pressure...2556
    Fuel injection timing...2557
    V-belt tension...2559
    Engine RPM...2560
    RPM-dependant drive take-up...2561
    Engine stall torque RPM...2562
      Engine stall torque RPM, test with the  hydrostatic drive...2562
      Engine stall torque RPM, test with  hydrostatic drive and working hydraulics...2563
    Feed pump (and servo oil pressure for WA80-5)...2564
    Hydraulic pressure cut-off...2565
    Working hydraulic pressure...2567
    Steering oil pressure...2568
      Testing...2568
      Adjusting...2569
    Operating time for steering wheel...2570
    Operating force of steering wheel...2570
    Disc brake (foot brake WA80-5)...2571
    Brake (WA65-5 and WA70-5)...2571
    Inch valve – basic adjustment...2572
      WA 65-5 and WA70-5...2572
      WA 80-5...2572
    Brake efficiency...2573
      Measuring the stopping distance...2573
    Parking brake efficiency...2574
    Travel speed...2575
  DISASSEMBLY AND ASSEMBLY...2576
    Comments...2578
    Starter assembly...2579
      Removal of starter assembly...2579
      Installation of starter assembly...2580
    Alternator assembly...2581
      Removal of alternator assembly...2581
      Installation of alternator assembly...2582
    Water pump assembly...2583
      Removal of water pump assembly...2583
      Installation of water pump assembly...2585
    Engine cover assembly...2586
      Removal of engine cover assembly...2586
      Installation of engine cover assembly...2587
    Engine cover support assembly...2588
      Removal of engine cover support assembly...2588
      Installation of engine cover support assembly...2589
    Engine assembly...2590
      Removal of engine assembly...2590
      Installation of engine assembly...2595
    Clutch assembly...2597
      Removal of clutch assembly...2597
      Installation of clutch assembly...2598
    Radiator assembly...2599
      Removal of radiator assembly...2599
      Installation of radiator assembly...2601
    Fan assembly...2602
      Removal of fan assembly...2602
      Installation of fan assembly...2603
    Inch brake valve assembly...2604
      Removal of inch brake valve assembly...2604
      Installation of inch brake valve assembly...2605
    Priority valve assembly...2606
      Removal of priority valve assembly...2606
      Installation of priority valve assembly...2607
    Orbit-roll-valve assembly...2608
      Removal of orbit-roll-valve assembly...2608
      Installation of orbit-roll-valve assembly...2610
    Counterweight assembly...2611
      Removal of counterweight assembly...2611
      Installation of counterweight assembly...2612
    Control valve assembly (WA65-5 / WA70-5)...2613
      Removal of control valve assembly...2613
      Installation of control valve assembly...2615
    Main control valve assembly (WA80-5)...2616
      Removal of main control valve assembly...2616
      Installation of main control valve assembly...2617
    Pilot valve assembly (WA80-5)...2618
      Removal of pilot valve assembly...2618
      Installation of pilot valve assembly...2619
    Monitor assembly...2620
      Removal of monitor assembly...2620
      Installation of monitor assembly...2621
    Articulated joint assembly...2622
      Removal of articulated joint assembly...2622
      Installation of articulated joint assembly...2623
    Variable motor assembly...2624
      Removal of variable motor assembly...2624
      Installation of variable motor assembly...2626
    Rear axle assembly...2627
      Removal of rear axle assembly...2627
      Installation of rear axle assembly...2629
    Front axle assembly...2630
      Removal of front axle assembly...2630
      Installation of front axle assembly...2632
    Front axle...2633
      Brake disc group...2633
      Disassembly...2633
      Assembly...2635
    Brake caliper...2637
      Hydraulic principle of operation...2637
      Differential position...2638
      Mechanical principle of operation...2638
      Caliper removal...2638
      Disassembly (calliper removed)...2639
      Disassembly...2639
      Assembly...2641
      Caliper reassembly...2643
      Replacement of guide protective covers...2643
      Pad replacement...2644
      Brake group - wheel shaft...2645
      Disassembly...2645
      Assembly...2648
    Rear axle...2651
      Trunnions group and flange...2651
      Disassembly...2651
      Assembly...2652
      Epicyclic reduction gear group...2654
      Disassembly...2654
      Assembly...2655
      Wheel hub...2656
      Disassembly...2656
      Assembly...2658
      Wheel shaft...2660
      Disassembly...2660
      Assembly...2661
      Differential support group...2662
      Disassembly...2662
      Assembly...2663
      Bevel gear marking test...2666
      Differential locking group...2667
      Disassembly...2667
      Assembly...2668
      Differential group (WA80-5)...2669
      Disassembly...2669
      Assembly...2670
      Differential group (WA65-5 / WA70-5)...2671
      Disassembly...2671
      Assembly...2672
      Pinion group...2673
      Disassembly...2673
      Assembly...2674
    Variable displacement pump assembly...2677
      Removal of variable displacement pump assembly...2677
      Installation of variable displacement pump assembly...2679
    Hydraulic pump assemblies...2680
      Removal of the two hydraulic pump assemblies...2680
      Installation of hydraulic pump assembly...2681
    Quick-attach coupler assembly...2682
      Removal of quick-attach coupler assembly...2682
      Installation of quick-attach coupler  assembly...2683
    Steering cylinder assembly...2684
      Removal of steering cylinder assembly...2684
      Installation of steering cylinder assembly...2685
    Lift cylinder assembly...2686
      Removal of lift cylinder assembly...2686
      Installation of lift cylinder assembly...2687
    Dump cylinder assembly...2688
      Removal of dump cylinder assembly...2688
      Installation of dump cylinder assembly...2689
    Replacing windows in driver’s cab...2690
      Stuck glass...2690
      Installation...2692
      Door and side windows...2693
      Door window assembly...2693
      Side window assembly...2693
  OTHERS...2694
    Wiring diagram1/5...2704
    Wiring diagram 2/5...2706
    Wiring diagram 3/5...2708
    Wiring diagram 4/5...2710
    Wiring diagram 5/5...2712
    Wiring diagram, Speed control...2714
    Wiring diagram, Immobilizer...2716
    Hydraulic circuit diagram 1/4...2696
    Hydraulic circuit diagram 2/4...2698
    Hydraulic circuit diagram 3/4...2700
    Hydraulic circuit diagram 4/4...2702
VEBM270100 - Wheel Loader WA90-5, WA100M-5 Shop Manual...2718
  SAFETY...2720
    Safety notice...2722
      Preparations for work...2723
      Tipping up the driver's cab...2723
      Tipping down the driver's cab...2725
      Tipping up the driver's cab (option with electric actuator)...2727
      Tipping down the driver's cab (option with electric actuator)...2729
      Precautions during work...2730
      Hydraulic system...2731
    Foreword...2732
    How to read the shop manual...2733
      Volumes...2733
      Distribution and updating...2733
      Filing method...2733
      Symbols...2734
    Hoisting instructions...2735
      Wire ropes...2735
  GENERAL...2738
    Dimensions, weights and operating data WA90-5...2740
    Specifications WA90-5...2741
    Weight table WA90-5...2742
    Dimensions, weights and operating data WA100M-5...2743
    Specifications WA100M-5...2744
    Weight table WA100M-5...2745
    Lubricants and operating mediums: WA90-5...2747
    Lubricants and operating mediums: WA100M-5...2748
    Basic procedures of maintenance...2749
      Oil...2749
      Fuel...2749
      Coolant...2750
      Grease...2750
      Storing oil and fuel...2750
      Filters...2751
      Biodegradable hydraulic oils and lubricants...2751
      Outline of electric system...2751
    Torque list - screws and nuts...2752
  STRUCTURE AND FUNCTION...2754
    Steering system...2785
      Hydraulic circuit diagram of steering system...2785
    Powertrain...2756
    Closed circuit...2757
    Hydraulic drive system...2758
      20km/h and 30km/h...2758
    Variable displacement pump...2759
      Regulating valve...2762
      Charge pressure limiting valve...2762
      Control cylinder...2763
      4/3 Way valve with direction control solenoids...2763
      Pressure cut-off valve...2764
      Safety-/charge valve...2764
      Towing...2765
    Variable displacement motor...2766
    Drive shaft...2768
    Axle mounting - front axle...2769
    Axle mounting - rear axle...2769
    Front axle...2770
      With inner disc brake as service brake and outer disc brake as parking brake...2770
    Rear axle with transfer box...2771
    Transfer box TB172...2772
    Limited slip differential...2773
      locking value 25%...2773
    Locking differential...2775
      locking value 100%...2775
    Wheel hub, front and rear axle...2777
    Service brake, front axle...2778
    Parking brake, front axle...2779
    Service and parking brake circuit...2780
    Service brake assembly...2781
    Main-brake Valve...2782
    Steering articulation joint...2783
      Priority valve...2787
      Orbit-roll-valve...2788
      Steering relief valve...2789
    Work equipment hydraulic...2791
      Travel, steering and work hydraulics...2791
    PPC-Valve...2793
      Operation of PPC-valve...2794
      Servo pressure regulating valve...2795
      Emergency Lowering System...2795
    Main control valve...2797
    WA90-5: Lift cylinder...2799
    WA100M-5: Lift cylinder...2800
    WA90-5: Dump cylinder...2801
    WA100M-5: Dump cylinder...2802
    Steering cylinder...2803
    Loader Linkage with quick-coupler...2805
    Quick-coupler...2806
    Monitor display...2807
    Sensors...2808
      Engine oil pressure sensor...2808
      Fuel level sensor...2809
      Engine coolant temperature sensor...2810
      Brake oil reservoir sensor...2811
    Ribbon heater...2812
    Engine stop / start / preheating circuit...2813
    Electrical fuses and relays...2815
      Fuses...2815
      Relays...2816
      Engine room...2817
    Electrical diagrams...2818
      Wiring diagram 1/5 - foldout 90-9...2818
      Wiring diagram 2/5 - foldout 90-11...2818
      Wiring diagram 3/5 - foldout 90-13...2818
      Wiring diagram 4/5 - foldout 90-15...2818
      Wiring diagram 5/5 - foldout 90-17...2818
      Speed control - foldout 90-19...2818
      Immobilizer - foldout 90-21...2818
    Air conditioner (option)...2819
      Introduction...2819
      Function...2820
        The coolant circuit...2820
        The condenser...2822
        The vaporizer...2823
        The filter dryer...2824
      Installation of air conditioner...2826
      Safety when handling coolants...2827
      Operating the air conditioner...2829
      Maintenance of the air conditioner...2830
        Regular maintenance...2831
      Instructions for filling...2833
      Exchange of magnetic clutch...2836
      Exchange of compressor...2837
      Troubleshooting...2839
  TESTING AND ADJUSTING...2844
    Standard value table for engine - WA90-5 / WA100M-5...2846
    Standard value table for chassis - WA90-5...2847
    Standard value table for chassis - WA100M-5...2849
    Standard value table for electrical parts...2851
    Test certificate - WA90-5...2852
    Test certificate - WA100M-5...2853
    Valve lash clearance...2854
    Engine compression test...2856
    Injection nozzle pressure...2857
    Fuel injection timing...2858
    V-belt tension...2860
    Engine RPM...2861
    RPM-dependant drive take-up...2862
    Engine stall torque RPM...2863
      Engine stall torque RPM, test with the hydrostatic drive...2863
      Engine stall torque RPM, test with hydrostatic drive and working hydraulics...2864
    Feed pump and servo oil pressure...2865
    Hydraulic pressure cut-off...2866
    Working hydraulic pressure...2868
    Steering oil pressure...2869
      Testing...2869
      Adjusting...2870
    Pressure Accumulator...2871
    Operating time for steering wheel...2872
    Operating force of steering wheel...2872
    Disc brake...2873
    Inch valve - basic adjustment...2874
    Brake efficiency...2875
      Measuring the stopping distance...2875
    Parking brake efficiency...2876
    Travel speed...2878
  DISASSEMBLY AND ASSEMBLY...2880
    Comments...2882
    Starter assembly...2883
      Removal of starter assembly...2883
      Installation of starter assembly...2884
    Alternator assembly...2885
      Removal of alternator assembly...2885
      Installation of alternator assembly...2886
    Water pump assembly...2887
      Removal of water pump assembly...2887
      Installation of water pump assembly...2889
    Engine cover assembly...2890
      Removal of engine cover assembly...2890
      Installation of engine cover assembly...2891
    Engine cover support assembly...2892
      Removal of engine cover support assembly...2892
      Installation of engine cover support assembly...2893
    Engine assembly...2894
      Removal of engine assembly...2894
      Installation of engine assembly...2900
    Clutch assembly...2902
      Removal of clutch assembly...2902
      Installation of clutch assembly...2903
    Radiator assembly...2904
      Removal of radiator assembly...2904
      Installation of radiator assembly...2906
    Fan assembly...2907
      Removal of fan assembly...2907
      Installation of fan assembly...2908
    Main brake cylinder assembly...2909
      Removal of main brake cylinder assembly...2909
      Installation of main brake cylinder assembly...2910
    Priority valve assembly...2911
      Removal of priority valve assembly...2911
      Installation of priority valve assembly...2912
    Orbit-roll-valve assembly...2913
      Removal of orbit-roll-valve assembly...2913
      Installation of orbit-roll-valve assembly...2915
    Counterweight assembly...2916
      Removal of counterweight assembly...2916
      Installation of counterweight assembly...2917
    Main control valve assembly...2918
      Removal of main control valve assembly...2918
      Installation of main control valve assembly...2919
    Pilot valve assembly...2920
      Removal of pilot valve assembly...2920
      Installation of pilot valve assembly...2921
    Monitor assembly...2922
      Removal of monitor assembly...2922
      Installation of monitor assembly...2923
    Articulated joint assembly...2924
      Removal of articulated joint assembly...2924
      Installation of articulated joint assembly...2925
    Variable motor assembly...2926
      Removal of variable motor assembly...2926
      Installation of variable motor assembly...2928
    Rear axle assembly...2929
      Removal of rear axle assembly...2929
      Installation of rear axle assembly...2931
    Front axle assembly...2932
      Removal of front axle assembly...2932
      Installation of front axle assembly...2934
    Front axle...2935
      Brake disc group...2935
        Disassembly...2935
        Assembly...2937
    Brake caliper...2939
      Hydraulic principle of operation...2939
      Differential position...2940
      Mechanical principle of operation...2940
      Caliper removal...2940
        Disassembly (calliper removed)...2941
        Disassembly...2941
        Assembly...2943
      Caliper reassembly...2945
      Replacement of guide protective covers...2945
      Pad replacement...2946
      Brake group - wheel shaft...2947
        Disassembly...2947
        Assembly...2950
    Rear axle...2953
      Trunnions group and flange...2953
        Disassembly...2953
        Assembly...2954
      Epicyclic reduction gear group...2956
        Disassembly...2956
        Assembly...2957
      Wheel hub...2958
        Disassembly...2958
        Assembly...2960
      Wheel shaft...2962
        Disassembly...2962
        Assembly...2963
      Differential support group...2964
        Disassembly...2964
        Assembly...2965
      Bevel gear marking test...2969
      Differential locking group...2970
        Disassembly...2970
        Assembly...2971
      Differential group (100% Diff. Lock)...2972
        Disassembly...2972
        Assembly...2973
      Differential group (LSD 25%)...2974
        Disassembly...2974
        Assembly...2975
      Pinion group...2976
        Disassembly...2976
        Assembly...2977
    Variable displacement pump assembly...2980
      Removal of variable displacement pump assembly...2980
      Installation of variable displacement pump assembly...2982
    Hydraulic pump assemblies...2983
      Removal of the two hydraulic pump assemblies...2983
      Installation of hydraulic pump assembly...2984
    Turbocharger assembly...2985
      Removal of the turbocharger...2985
      Installation of the turbocharger...2985
    Quick-attach coupler assembly...2986
      Removal of quick-attach coupler assembly...2986
      Installation of quick-attach coupler assembly...2987
    Steering cylinder assembly...2988
      Removal of steering cylinder assembly...2988
      Installation of steering cylinder assembly...2989
    Lift cylinder assembly...2990
      Removal of lift cylinder assembly...2990
      Installation of lift cylinder assembly...2991
    Dump cylinder assembly...2992
      Removal of dump cylinder assembly...2992
      Installation of dump cylinder assembly...2993
    Replacing windows in driver’s cab...2994
      Stuck glass...2994
      Installation...2996
      Door and side windows...2997
        Door window assembly...2997
        Side window assembly...2997
  OTHERS...2998
  Hydraulic circuit diagram 1/3...3000
  Hydraulic circuit diagram 2/3...3002
  Hydraulic circuit diagram 3/3...3004
  Wiring diagram 1/5...3006
  Wiring diagram 2/5...3008
  Wiring diagram 3/5...3010
  Wiring diagram 4/5...3012
  Wiring diagram 5/5...3014
  Wiring diagram, Speed control...3016
  Wiring diagram, Immobilizer...3018
VEBM550101 - Wheel Loader WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6 Shop Manual...3019
  Contents...3021
  SAFETY...3031
    Safety notice...3036
      Preparations for work...3037
      Tipping up the driver's cab...3038
      Tipping down the driver's cab...3040
      Precautions during work...3042
      Hydraulic system...3043
    Foreword...3044
      General...3044
      Structure and function...3044
      Testing and adjusting...3044
      Disassembly and assembly...3044
      Maintenance standard...3044
    How to read the shop manual...3045
      Volumes...3045
      Distribution and updating...3045
      Filing method...3045
      Symbols...3046
    Hoisting instructions...3047
      Wire ropes...3047
  GENERAL...3049
    Dimensions, weights and operating data...3050
    Specifications...3052
      WA65-6 - Specifications...3052
      WA70-6 - Specifications...3053
      WA80-6 - Specifications...3054
      WA90-6 - Specifications...3055
      WA100M-6 - Specifications...3056
    Weight tables...3057
      WA65-6 - Weight table...3057
      WA70-6 - Weight table...3057
      WA80-6 - Weight table...3058
      WA90-6 - Weight table...3058
      WA100M-6 - Weight table...3059
    Lubricants and operating mediums...3060
      WA65-6, WA70-6 - Lubricants and operating mediums...3060
      WA80-6 - Lubricants and operating mediums...3061
      WA90-6 - Lubricants and operating mediums...3062
      WA100M-6 - Lubricants and operating mediums...3063
    Basic procedures of maintenance...3064
      Oil...3064
      Fuel...3064
      Coolant...3065
      Grease...3065
      Storing oil and fuel...3065
      Filters...3066
      Biodegradable hydraulic oils and lubricants...3066
      Outline of electric system...3066
    Torque list - Screws and nuts...3067
  STRUCTURE AND FUNCTION...3071
    Powertrain...3075
    Closed circuit...3076
    Hydraulic drive system...3077
      WA65-6, WA70-6 - Hydraulic drive system - 20 km/h...3077
      WA80-6 - Hydraulic drive system - 20 km/h and 30 km/h...3078
      WA90-6, WA100M-6 - Hydraulic drive system - 20 km/h and 30 km/h...3079
    Variable displacement pump (HST pump)...3080
      Regulating valve (DA valve)...3083
      WA65-6, WA70-6, WA80-6 - Charge pump pressure relief valve - 20km/h...3084
      WA80-6 ,WA90-6, 100M-6 - Charge pump pressure relief valve - 30km/h...3084
      Control cylinder...3085
      4/3 Way valve with direction control solenoids...3086
      Pressure cut-off valve...3087
      Safety & charge valve...3088
      Towing...3089
    Variable displacement motor (HST motor with HA Control)...3090
      Hydraulic diagram HST motor A6VM80 (or 160) HA1R1...3092
      Directional shuttle valve...3093
      Auto inch valve diagram (option)...3093
    HST motor with DA Control...3094
      Hydraulic diagram HST Motor A6VM107(160)DA2...3095
    Drive shaft...3096
    Front axle - Mounting...3097
      WA65-6, WA70-6 - Front axle mounting...3097
      WA80-6, WA90-6, WA100M-6 - Front axle mounting...3097
    Rear axle - Mounting...3098
    Front axle...3099
      WA65-6, WA70-6 - Front axle with outer disc brake as service brake and parking brake...3099
      WA80-6 - Front axle with inner disc brake as service brake and outer disc brake as parking brake...3100
      WA90-6, WA100M-6 - Front axle with inner disc brake as service brake and outer disc brake as parking brake...3101
    Rear axle with transfer box...3102
      WA65-6, WA70-6, WA80-6 - Rear axle with transfer box...3102
      WA90-6, WA100M-6 - Rear axle with transfer box...3103
    Trasfer box TB172...3104
    Limited slip differential...3106
      Limited slip differential - Locking value 25%...3106
    Locking differential...3108
      Locking differential - Locking value 100%...3108
    Wheel hub - Font axle and rear axle...3110
    Service and parking brake - Front axle...3112
      WA65-6, WA70-6 - Service and parking brake...3112
      WA80-6, WA90-6, WA100M-6 - Service brake...3114
      WA80-6, WA90-6, WA100M-6 - Parking brake...3115
    Service and parking brake circuit...3116
      WA65-6, WA70-6 - Service and parking brake circuit...3116
      WA80-6 - Service and parking brake circuit...3117
      WA90-6, WA100M-6 - Service and parking brake circuit...3118
    Service brake assembly...3119
      WA65-6, WA70-6 - Service brake assembly...3119
      WA80-6 - Service brake assembly...3120
      WA90-6, WA100M-6 - Service brake assembly...3121
    Main-brake valve...3122
      WA65-6, WA70-6 - Main-brake valve...3122
      WA80, WA90-6, WA100M-6 - Main-brake valve...3123
    Steering articulation joint...3124
    Steering system...3126
      WA65-6, WA70-6 - Hydraulic circuit diagram of steering system...3126
      WA80-6 - Hydraulic circuit diagram of steering system...3128
      WA90-6, WA100M-6 - Hydraulic circuit diagram of steering system...3130
      Priority valve...3132
      Orbit-roll-valve...3133
      Steering relief valve...3134
    Work equipment hydraulic...3136
      WA65-6, WA70-6 - Travel, steering and work hydraulics...3136
      WA80-6 - Travel, steering and work hydraulics...3138
      WA90-6, WA100M-6 - Travel, steering and work hydraulics...3140
    PPC-Valve WA90-6, WA100M-6...3142
      Operation of PPC-valve...3143
      Servo pressure regulating valve...3144
      Emergency Lowering System...3144
    Main control valve...3145
      Main control valve WA65-6, WA70-6, WA80-6...3145
      Main control valve WA90-6, WA100M-6...3146
    Lift cylinder...3147
      WA65-6, WA70-6 - Lift cylinder...3147
      WA80-6 - Lift cylinder...3148
      WA90-6 - Lift cylinder...3149
      WA100M-6 - Lift cylinder...3150
    Dump cylinder...3151
      WA65-6, WA70-6 - Dump cylinder...3151
      WA80-6 - Dump cylinder...3152
      WA90-6 - Dump cylinder...3153
      WA100M-6 - Dump cylinder...3154
    Steering cylinder...3155
      WA65-6, WA70-6 - Steering cylinder...3155
      WA80-6 - Steering cylinder...3156
      WA90-6, WA100M-6 - Steering cylinder...3157
    Loader Linkage with quick-coupler...3158
      WA65-6, WA70-6 - Loader Linkage with quick-coupler...3158
      WA80-6, WA90-6, WA100M-6 - Loader Linkage with quick-coupler...3159
    Quick-coupler...3160
      WA65-6, WA70-6 - Quick-coupler...3160
      WA80-6 - Quick-coupler...3161
      WA90-6, WA100M-6 - Quick-coupler...3162
    Monitor display...3164
      WA65-6, WA70-6, WA80-6 - Monitor display...3164
      WA90-6, WA100M-6 - Monitor display...3166
      Special monitor functions...3168
      Monitor panel adjustment...3169
        Adjustment switches...3169
        Adjustment table...3170
        WA65-6, WA70-6 Tire table...3172
        WA80-6 Tire table...3173
        WA90-6 Tire table...3174
        WA100M-6 Tire table...3175
      Reading error codes WA90-6, WA100M-6...3176
      Trouble Codes and Cummins Fault Codes...3177
    Sensors...3185
      Engine oil pressure sensor...3185
      Fuel level sensor...3186
      Engine coolant temperature sensor...3187
      Brake oil reservoir sensor...3188
    Pre-heater...3190
      WA65-6, WA70-6, WA80-6 - Glow plugs...3190
      WA90-6, WA100M-6 - Ribbon heater...3191
    Engine stop / start / preheating circuit...3192
      WA65-6, WA70-6, WA80-6...3192
      WA90-6, WA100M-6...3194
    Electrical fuses and relays...3196
      Fuses...3196
      Relays...3197
      Engine room...3198
    Diagrams...3199
      Wiring diagrams...3199
      Hydraulic circuit diagram...3199
    Air conditioner (option)...3200
      Introduction...3200
      Function...3201
        The coolant circuit...3201
        The condenser...3203
        The vaporizer...3204
        The filter dryer...3205
      Installation of air conditioner...3206
      Safety when handling coolants...3207
      Operating the air conditioner...3209
      Maintenance of the air conditioner...3210
        Regular maintenance...3211
      Instructions for filling...3213
      Exchange of magnetic clutch...3216
      Exchange of compressor...3217
      Troubleshooting...3219
  TESTING AND ADJUSTING...3221
    Standard value table for engine...3224
      WA65-6, WA70-6, WA80-6 - Standard value table for engine...3224
      WA90-6, WA100M-6 - Standard value table for engine...3225
    Standard value table for chassis...3226
      WA65-6 - Standard value table for chassis...3226
      WA70-6 - Standard value table for chassis...3228
      WA80-6 - Standard value table for chassis...3230
      WA90-6 - Standard value table for chassis...3232
      WA100M-6 - Standard value table for chassis...3234
    Standard value table for electrical parts...3236
    Test certificate...3237
      WA65-6 - Test certficate...3237
      WA70-6 - Test certificate...3238
      WA80-6 - Test certificate...3239
      WA90-6 - Test certificate...3240
      WA100M-6 - Test certificate...3241
    Valve lash clearance...3242
      WA65-6, WA70-6, WA80-6 - Valve lash clearance...3242
      WA90-6, WA100M-6 - Valve lash clearance...3244
    Engine compression test...3246
      WA65-6, WA70-6, WA80-6 - Engine compression test...3246
      WA90-6, WA100M-6 - Engine compression test...3247
      Testing blow-by pressure...3250
    Fuel system...3251
      Handling fuel system parts...3251
      Releasing residual pressure in fuel system...3251
      WA65-6, WA70-6, WA80-6 - Adjusting fuel injection pressure (cracking pressure)...3252
      WA65-6, WA70-6, WA80-6 - Shim data for adjusting injection pressure...3253
      WA65-5, WA70-6, WA80-6 - Testing and adjusting fuel injection timing...3254
      WA90-6, WA100M-6 - Testing fuel pressure...3258
        Reduced cylinder mode operation...3259
        No-injection cranking...3259
      WA90-6, WA100M-6 - Testing leakage from pressure limiter and return rate from injector...3260
      WA90-6, WA100M-6 - Bleeding air from fuel circuit...3263
      WA90-6, WA100M-6 - Testing fuel system for leakage...3265
    V-belt tension...3266
    Engine RPM...3267
    Testing travel speed...3268
    Engine stall torque RPM...3269
      Engine stall torque RPM, test with the hydrostatic drive...3270
      Engine stall torque RPM, test with hydrostatic drive and working hydraulics...3271
      Feed pump (and servo oil pressure)...3272
        WA90-6 and WA100M-6...3272
    Hydraulic pressure cut-off...3273
    Working hydraulic pressure...3275
    Steering oil pressure...3276
      Testing...3276
      Adjusting...3277
    Operating time for steering wheel...3278
    Operating force of steering wheel...3279
    Disc brake (foot brake)...3280
      WA80-6, WA90-6, WA100M-6 - Disc brake (foot brake)...3280
    Brake...3281
      WA65-6, WA70-6 - Brake...3281
    Main brake valve - basic adjustment...3282
      WA65-6, WA70-6...3282
      WA80-6, WA90-6, WA100M-6...3282
    Brake efficiency...3283
      Measuring the stopping distance...3283
    Parking brake efficiency...3284
    Bleeding/ filling up the brake circuit...3285
      WA65-6, WA70-6 - Bleeding/ filling up the brake circuit...3285
    Ventilation / filling up the brake circuit...3287
      WA80-6, WA90-6, WA100M-6 - Ventilation / filling up the brake circuit...3287
    Cabin - adjustment...3288
    Proportional amplifier...3289
  DISASSEMBLY AND ASSEMBLY...3291
    Comments...3295
    Starter assembly...3296
      Removal of starter assembly...3296
      Installation of starter assembly...3297
    Alternator assembly...3298
      Removal of alternator assembly...3298
      Installation of alternator assembly...3299
    Radiator assembly...3300
      Removal of radiator assembly...3300
      Installation of radiator assembly...3304
    Fan assembly...3305
      Removal of fan assembly...3305
      Installation of fan assembly...3306
    Water pump assembly...3307
      Removal of water pump assembly...3307
      Installation of water pump assembly...3309
    Fuel tank assembly...3310
      Removal and installation of fuel tank assembly...3310
        Installation...3310
    Engine cover assembly...3311
      Removal of engine cover assembly...3311
      Installation of engine cover assembly...3312
    Engine cover support assembly...3313
      Removal of engine cover support assembly...3313
      Installation of engine cover support assembly...3314
    Engine assembly...3315
      Removal of engine assembly...3315
      Installation of engine assembly...3321
    Clutch assembly...3323
      Removal of clutch assembly...3323
      Installation of clutch assembly...3324
    Main brake valve assembly...3325
      Removal of main brake valve assembly...3325
      Installation of main brake valve assembly...3326
    Priority valve assembly...3327
      Removal of priority valve assembly...3327
      Installation of priority valve assembly...3328
    Orbit-roll-valve assembly...3329
      Removal of orbit-roll-valve assembly...3329
      Installation of orbit-roll-valve assembly...3331
    Counterweight assembly...3332
      Removal of counterweight assembly...3332
      Installation of counterweight assembly...3334
    Main control valve assembly - WA65-6, WA70-6, WA80-6...3335
      Removal of control valve assembly...3335
      Installation of main control valve assembly...3337
    Main control valve assembly - WA90-6, WA100M-6...3338
      Removal of main control valve assembly...3338
      Installation of main control valve assembly...3339
    Pilot valve assambly WA90-6, WA100M-6...3340
      Removal of pilot valve assembly...3340
      Installation of pilot valve assembly...3342
    Monitor assembly...3343
      Removal of monitor assembly...3343
      Installation of monitor assembly...3344
    Articulated joint assembly...3345
      Removal of articulated joint assembly...3345
      Installation of articulated joint assembly...3346
    Variable motor assembly...3347
      Removal of variable motor assembly...3347
      Installation of variable motor assembly...3349
    Rear axle assembly...3350
      Removal of rear axle assembly...3350
      Installation of rear axle assembly...3352
    Front axle assembly...3353
      Removal of front axle assembly...3353
      Installation of front axle assembly...3355
    Front axle...3356
      Brake disc group...3356
      Disassembly...3356
        Assembly...3358
    Brake caliper...3360
      Hydraulic principle of operation...3360
      Differential position...3361
      Mechanical principle of operation...3361
      Caliper removal...3361
        Disassembly (calliper removed)...3362
        Disassembly...3362
        Assembly...3364
      Caliper reassembly...3366
      Replacement of guide protective covers...3366
      Pad replacement...3367
    Brake group - wheel shaft...3368
      Disassembly...3368
      Assembly...3371
    Rear axle...3374
      Trunnions group and flange...3374
      Disassembly...3374
      Assembly...3375
    Epicyclic reduction gear group...3377
      Disassembly...3377
      Assembly...3378
    Wheel hub...3379
      Disassembly...3379
      Assembly...3381
    Wheel shaft - WA65-6, WA70-6...3383
      Disassembly...3383
      Assembly...3384
    Wheel shaft - WA80-6, WA90-6, WA100M-6...3385
      Disassembly...3385
      Assembly...3386
    Differential support group...3387
      Disassembly...3387
      Assembly...3388
      Bevel gear marking test...3392
    Differential locking group...3393
      Disassembly...3393
      Assembly...3394
    Differential group (100% Differential Lock)...3395
      Disassembly...3395
      Assembly...3396
    Differential group (LSD 25%)...3397
      Disassembly...3397
      Assembly...3398
    Pinion group...3399
      Disassembly...3399
      Assembly...3400
    Transmission box...3403
      Disassembly...3403
      Assembly...3408
    Variable displacement pump assembly...3413
      Removal of variable displacement pump assembly...3413
      Installation of variable displacement pump assembly...3415
    Hydraulic pump assemblies...3416
      Removal of the two hydraulic pump assemblies...3416
      Installation of hydraulic pump assembly...3417
    Turbocharger assembly - WA80-6, WA90-6, WA100M-6...3418
      Removal of the turbocharger...3418
      Installation of the turbocharger...3418
    Quick coupler assembly...3419
      Removal of quick coupler assembly...3419
      Installation of quick coupler assembly...3420
    Steering cylinder assembly...3421
      Removal of steering cylinder assembly...3421
      Installation of steering cylinder assembly...3422
    Lift cylinder assembly...3423
      Removal of lift cylinder assembly...3423
      Installation of lift cylinder assembly...3424
    Dump cylinder assembly...3425
      Removal of dump cylinder assembly...3425
      Installation of dump cylinder assembly...3426
    Replacing windows in driver’s cab...3427
      Stuck glass...3427
      Installation...3429
      Door and side windows...3430
        Door window assembly...3430
        Side window assembly...3430
  others...3431
    Hydraulic circuit diagram - WA65-6, WA70-6...3433
    Hydraulic circuit diagram - WA80-6...3434
    Hydraulic circuit diagram - WA90-6, WA100M-6...3435
    Wiring diagram 2/9 - WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6...3437
    Wiring diagram 8/9 - WA90-6, WA100M-6...3443
    Wiring diagram 3/9 - WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6...3438
    Wiring diagram 4/9 - WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6...3439
    Wiring diagram 5/9 - WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6...3440
    Wiring diagram 6/9 - WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6...3441
    Wiring diagram 7/9 - WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6...3442
    Wiring diagram 9/9 - WA65-6, WA70-6, WA80-6-6...3444
    Wiring diagram 1/9 - WA90-6, WA100M-6...3436
VFAM260100 - Chargeuse sur Roues WA80-5 Instructions de Service et de Maintenance...3445
  WA80-5_VFAM260100_0410...3445
    1.  Introduction...3446
      1.1.  Préface...3447
        Directives UE...3448
      1.2.  Informations pour la sécurité technique...3450
      1.3.  Introduction...3452
        1.3.1.  Utilisation conforme...3452
        1.3.2.  Rodage de l'engin...3453
      1.4.  Données caractéristiques de l'engin...3454
        1.4.1.  PIN/Plaques d’identification de la machine...3454
        1.4.2.  Emplacement du n de série du moteur...3454
        1.4.7.  Tableau destiné au n de série et au nom du concessionnaire...3456
      1.5.  Sommaire...3459
      1.6.  Dimensions, poids et valeurs opérationnelles...3466
      1.7.  Equipement conforme CE...3467
        1.7.1.  Equipement conforme CE - 1ère partie...3467
        1.7.2.  Equipement conforme CE - 2ème partie...3467
        1.7.3.  Conformité CE de l’équipement du fabricant...3468
      1.8.  Chargement et blocage de sécurité...3471
    2.  Sécurité...3474
      2.1.  Consignes générales de sécurité...3475
        2.1.1.  Consignes de sécurité...3475
        2.1.2.  Dispositifs de protection...3475
        2.1.3.  Sortie de secours...3475
        2.1.4.  Vêtements et protection personnelle...3476
        2.1.5.  Modifications sur l’engin...3476
        2.1.6.  Avant de quitter l'engin...3476
        2.1.7.  Montée et descente...3477
        2.1.8.  Protection contre les incendies...3477
        2.1.9.  Protection contre les poussières d’amiante...3478
        2.1.10.  Protection contre les blessures...3478
        2.1.11.  Comment travailler à des températures élevées...3479
        2.1.12.  Protection contre le retournement (ROPS)...3479
        2.1.13.  Protection contre la chute d'objets (FOPS)...3480
        2.1.14.  Equipement supplémentaire...3480
        2.1.15.  Batterie...3481
      2.2.  Mesures de sécurité pendant le fonctionnement...3482
        2.2.1.  Avant la mise en marche quotidienne...3482
          Sécurité sur le poste de travail...3482
          Dans la cabine du conducteur...3482
          Fonctionnement dans des pièces fermées...3483
          Gaz, poussières et vapeurs inflammables...3483
          Rétroviseurs, vitres et éclairage...3483
        2.2.2.  Fonctionnement de l’engin...3484
          Avant le lancement du moteur...3484
          Marche arrière...3484
          Pendant le déplacement...3485
          Déplacement à flanc de coteaux...3485
          Abaissement de secours...3486
          Travail à proximité de lignes électriques aériennes...3487
          Lors du chargement...3488
          Bonne visibilité...3488
          Comment travailler dans la neige...3488
          Limitation de hauteur...3489
          Freinage...3489
          Travail sur des sols meubles...3489
          Comment travailler avec l’adaptateur pour chariot élévateur...3489
          Stationnement de l’engin...3491
        2.2.3.  Transport...3492
          Mesures de sécurité lors du transport...3492
          Transport...3492
      2.3.  Mesures de sécurité pour la maintenance...3493
        2.3.1.  Personnel...3493
        2.3.2.  Avant d'effectuer les opérations de maintenance ...3493
        2.3.3.  Pendant la maintenance...3500
        2.3.4.  Pneumatiques...3504
      2.4.  Autocollants de sécurité...3506
        2.4.1.  Emplacement des autocollants de sécurité...3506
    3.  Commande...3510
      3.1.  Vue d'ensemble...3511
        3.1.1.  Vue d'ensemble de l'engin...3511
        3.1.2.  Organes de commande et de contrôle...3512
          Vue d'ensemble...3512
          Contacteurs, éléments de contrôle et témoins d’alerte...3513
      3.2.  Fonction des composants...3514
        3.2.1.  Tableau de bord...3514
          Témoins d’alerte...3515
          Témoins de contrôle...3517
          Indicateurs de mesure...3521
        3.2.2.  Contacteurs...3523
        3.2.3.  Leviers de commande, pédales...3530
        3.2.4.  Blocage du joint d’articulation...3535
        3.2.5.  Dispositif de traction...3535
        3.2.6.  Prise de courant...3536
        3.2.7.  Déverrouillage de la porte et des fenêtres...3536
        3.2.8.  Avertisseur sonore de recul – option...3536
        3.2.9.  Fusibles...3537
        3.2.10.  Fusibles principaux, relais...3538
        3.2.11.  Réglage du système de chauffage et de ventilation...3539
        3.2.12.  Fonctionnement du climatiseur...3540
      3.3.  Contrôles avant le lancement...3541
        3.3.1.  Contrôles avant le lancement du moteur...3541
          Faire le tour de la machine...3541
          Contrôles avant le lancement...3543
          Réglages avant le démarrage...3548
        3.3.2.  Lancement du moteur...3552
          Mise à température du moteur...3553
        3.3.3.  Rouler avec l'engin...3554
          Démarrage...3554
        3.3.4.  Modification du sens de marche...3556
        3.3.5.  Tourner et braquer...3557
        3.3.6.  Freiner...3558
        3.3.7.  Arrêt de la machine...3560
        3.3.8.  Actionnement de l’équipement de travail...3561
          Levier multifonctions...3561
          Levier de commande pour équipements spéciaux...3562
          Levier de commutation du godet...3563
        3.3.9.  Comment travailler avec la chargeuse sur roues...3564
          Comment travailler en ménageant les pneumatiques...3564
          Mise en marche du blocage de différentiel 100% (si installé)...3565
          Opérations de chargement...3566
          Opérations de déblaiement...3566
          Opérations de cavage...3568
          Opérations de nivellement...3569
          Transport...3570
          Opérations de déchargement...3570
          Comment travailler avec l’adaptateur pour chariot élévateur...3571
        3.3.10.  Précautions durant le travail...3573
          Profondeur d´immersion permise dans l´eau...3573
          Opérations sur la neige...3573
          Pendant le chargement...3573
          Travail à proximité de lignes électriques aériennes...3573
          Déplacement à flanc de coteaux...3573
          Travail sur des sols meubles...3573
          En cas de défaillance du frein de service...3573
          Précautions à la montée ou la descente d´une pente...3574
          Précautions en cours de déplacement...3575
        3.3.11.  Réglage du positionnement de l´équipement de travail...3576
          Sélectionner l’appareil de travail...3576
          Retrait du godet...3578
          Montage du godet multi-usages...3579
          Retrait du godet multi-usages...3581
          Indicateurs de niveau du godet...3581
        3.3.12.  Stationnement de la machine...3582
        3.3.13.  Couper le moteur...3583
        3.3.14.  Contrôles aprés l’arrêt du moteur...3583
        3.3.15.  Verrouillage...3583
        3.3.16.  Pneumatiques...3584
          Précautions à prendre avec les pneumatiques...3584
          Pression des pneumatiques...3584
      3.4.  Transport...3586
        3.4.1.  Blocage du joint d’articulation...3586
        3.4.2.  Levage de l’engin...3587
        3.4.3.  Comment charger un engin sur un véhicule de transport...3588
        3.4.4.  Freinage de l’engin pendant le transport...3589
        3.4.5.  Après le transport...3589
      3.5.  Utilisation par temps froids...3590
        3.5.1.  Avant la saison froide...3590
        3.5.2.  Précautions en fin de travail...3591
        3.5.3.  Après la saison froide...3591
      3.6.  Remisage de longue durée...3592
        3.6.1.  Avant le remisage...3592
        3.6.2.  Durant le remisage...3592
        3.6.3.  Aprés le remisage...3593
    4.  Recherche et élimination des défauts...3594
      4.1.  Remorquage de l’engin...3595
      4.2.  Lancement du moteur avec câbles de pontage...3599
      4.3.  En cas de puissance insuffisante de freinage...3601
        4.3.1.  Contrôle du frein de stationnement...3601
        4.3.2.  Contrôle du frein de service...3601
      4.4.  Direction de secours...3602
      4.5.  Abaissement de secours...3602
      4.6.  Autres problèmes...3603
        4.6.1.  Système électrique...3603
        4.6.2.  Moteur...3604
        4.6.3.  Système hydraulique...3607
        4.6.4.  Frein...3609
        4.6.5.  Direction...3609
        4.6.6.  Essieux...3610
        4.6.7.  Cabine du conducteur...3610
    5.  Maintenance...3612
      5.1.  Guide pour l'entretien...3613
      5.2.  Opérations d'entretien fondamentales...3621
        5.2.1.  Indications relatives aux lubrifiants et aux moyens d'exploitation...3621
          Huile...3621
          Carburant...3622
          Liquide de refroidissement...3623
          Graisse...3623
          Stockage d'huile et de carburant...3624
          Filtres...3624
          Huiles hydrauliques et graisses biodégradables...3624
        5.2.2.  Indications concernant le système électrique...3625
        5.2.3.  Liste des pièces d'usure...3626
      5.3.  Graisses, lubrifiants et pleins...3627
      5.4.  Outils et couples de serrage (vis,  écrous)...3628
        5.4.1.  Outillage nécessaire...3628
        5.4.2.  Couples de serrage...3629
      5.5.  Remplacement régulier des pièces touchant à la sécurité...3631
      5.6.  Calendrier de maintenance...3632
      5.7.  Procédure de maintenance...3634
        5.7.1.  Maintenance avant le démarrage...3634
          Système de refroidissement – contrôle et complément du plein de liquide de refroidissement...3634
          Nettoyage des lamelles de refroidissement...3635
          Courroie trapézoïdale: contrôle de l’état...3635
          Moteur: contrôle et complément du plein d’huile...3635
          Contrôle et complément du plein de carburant...3637
          Evacuateur d'eau du filtre de carburant – Evacuer l’eau et les dépôts de crasse...3638
          Pompe manuelle - Contrôle du niveau d’huile...3639
          Contrôle des éléments de contrôle...3639
          Contrôle des raccords électriques...3640
          Chauffage/climatiseur – contrôle du débit d’air...3640
          Autres contrôles avant le début des opérations...3641
        5.7.2.  Maintenance en cas de besoin...3642
          Contrôle du climatiseur...3642
          Contrôle du niveau de liquide de lave-glace – complément du plein...3644
          Chargement d’une batterie montée...3644
        5.7.3.  Maintenance aprés les premieres 50 heures de service...3645
          Système hydraulique: remplacement de la garniture filtrante...3645
          Contrôle, resserrage des écrous de roues...3646
        5.7.4.  Maintenance aprés les premieres 250 heures de service...3647
          Essieu avant et essieu arrière: vidange d’huile...3647
          Convertisseur – vidange d’huile...3648
          Contrôle et réglage du jeu des soupapes...3648
        5.7.5.  Maintenance toutes les 10 heures de service...3649
          Graissage...3649
        5.7.6.  Maintenance toutes les 50 heures de service...3650
          Frein de service: contrôle du niveau d’huile et complément du plein...3650
          Batterie: contrôle du niveau de l’acide...3651
          Graissage...3652
        5.7.7.  Maintenance toutes les 250 heures de service...3653
          Courroie trapézoïdale de la dynamo – contrôle et réglage de la tension...3653
          Filtre d’air: démontage et montage de la garniture filtrante, contrôle et nettoyage de la garnitu...3654
          Graissage: vérin...3657
          Graissage: palier articulé de l'essieu...3658
        5.7.8.  Maintenance toutes les 500 heures de service...3659
          Moteur – vidange de l’huile et remplacement de la cartouche du filtre d’huile...3659
          Remplacement de la cartouche filtrante...3660
          Filtre de carburant, remplacement de la cartouche filtrante...3661
          Purge du carburateur...3662
          Purger le côté basse pression:...3662
          Purger le côté haute pression...3662
          Filtre d’air: remplacement de la garniture filtrante, remplacement du filtre de sécurité...3663
          Chauffage/climatiseur – nettoyage/remplacement du filtre en fibres ou remplacement du condenseur...3664
          Contrôle de la pression du gaz dans l'accumulateur de l'E.C.S.S. (option)...3665
          Essieu avant et essieu arrière: contrôle du niveau d’huile...3666
          Convertisseur: contrôle du niveau d’huile, complément du plein...3667
        5.7.9.  Maintenance toutes les 1000 heures de service...3668
          Courroie trapézoïdale de la dynamo – contrôle et réglage de la tension...3668
          Frein de service – contrôle, réglage, vidange d'huile...3668
          Contrôle et réglage des pressions du système...3668
          Remplacement du filtre de purge/aération du système hydraulique...3669
          Système hydraulique: remplacement de la garniture filtrante...3670
        5.7.10.  Maintenance toutes les 1500 heures de service...3671
          Essieu avant et essieu arrière: vidange d’huile...3671
          Convertisseur – vidange d’huile...3673
        5.7.11.  Maintenance toutes les 2000 heures de service...3674
          Système de refroidissement: remplacement du liquide de refroidissement et nettoyage du système...3674
          Contrôle et réglage du jeu des soupapes...3676
          Système hydraulique – vidange d’huile...3677
          Système hydraulique: aération du réservoir d’huile hydraulique...3678
          Contrôle de la pompe d’alimentation...3679
          Contrôle, éventuellement remplacement des durites de carburant et des flexibles d’eau de refroidi...3679
          Contrôle de la pompe d’eau...3679
        5.7.12.  Maintenance toutes les 4000 heures de service...3680
          Graissage...3680
    6.  Caractéristiques techniques...3682
      6.1.  Caractéristiques techniques...3683
      6.2.  Emission sonore...3684
      6.3.  Niveau d'oscillations...3684
      6.4.  Valeurs limites pour les montées...3684
    7.  Equipement spécial, équipement de travail...3686
      7.1.  Système électronique E.C.S.S...3687
        7.1.1.  Structure et fonctionnement du système électronique E.C.S.S...3687
        7.1.2.  Mesures préventives lors de l'enclenchement du système électronique E.C.S.S...3687
        7.1.3.  Commande du système électronique E.C.S.S...3688
          Enclenchement  du système électronique E.C.S.S...3688
          Coupure  du système électronique E.C.S.S...3688
        7.1.4.  Mesures préventives lors de la manipulation d'accumulateurs de pression...3689
    8.  Index...3690
    9.  Notes...3696
VFAM550102 - Chargeuse sur Roues WA65-6, WA70-6, WA80-6, WA90-6, WA100M-6 Instructions de Service et de Maintenance...3702
  1. Avant-propos...3704
    1.1 Avant-propos...3705
      Directives européennes...3707
    1.2 Informations relatives à la sécurité...3709
      1.2.1 Termes d'avertissement...3709
      1.2.2 Etiquettes de sécurité...3711
    1.3 Introduction...3712
      1.3.1 Utilisation conforme...3712
    1.4 Données caractéristiques de l'engin...3714
      1.4.1 Numéro d'identification du produit (PIN) / Plaquette et position du n de série de l'engin...3714
      1.4.2 Plaquette portant le n de série du moteur...3715
      1.4.3 Plaquette portant le n de série des essieux...3715
      1.4.4 Plaquette portant le n de série de la transmission...3715
      1.4.5 Plaquette portant le n de série de la cabine de sécurité à structure de protection contre le retournement, le renversement et la chute d'objets (cabine ROPS/FOPS)...3716
      1.4.6 Plaquette portant le n de série du siège de l'opérateur...3716
      1.4.7 Tableau destiné aux n de série et au concessionnaire...3717
      1.4.8 Déclaration de conformité (pour les engins mis sur le marché à partir du 29 décembre 2009)...3718
    1.5 Table des matières...3719
    1.6 Dimensions, poids et caractéristiques de service...3727
      1.6.1 WA65-6, WA70-6, WA80-6...3727
      1.6.2 WA90-6, WA100M-6...3729
    1.7 Equipements conformes CE...3731
      1.7.1 Equipement conforme CE - Partie 1...3731
      1.7.2 Equipement conforme CE - Partie 2...3733
      1.7.3 Conformité CE des équipements fournis par d'autres fabricants...3734
  2. Sécurité...3740
    2.1 Etiquettes de sécurité...3741
      2.1.1 Emplacement des étiquettes de sécurité...3741
    2.2 Précautions générales...3743
    2.3 Précautions à prendre durant le travail...3755
      2.3.1 Démarrage du moteur...3755
      2.3.2 Opération...3757
      2.3.3 Transport...3765
      2.3.4 Batterie...3766
    2.4 Précautions à prendre pour la maintenance...3768
  3. Opération...3780
    3.1 Vue d'ensemble...3781
      3.1.1 Vue d'ensemble de l'engin...3781
      3.1.2 Eléments de commande et de contrôle...3783
        Vue d'ensemble...3783
      3.1.3 Tableau des instruments de contrôle...3785
      3.1.4 Commutateurs...3787
    3.2 Description des différents éléments...3789
      3.2.1 Tableau de bord...3789
        Témoins d'avertissement...3790
        Témoins de contrôle...3793
        Instruments de mesure...3799
      3.2.2 Commutateurs...3801
      3.2.3 Leviers de commande et pédales...3811
      3.2.4 Verrouillage du joint d'articulation...3816
      3.2.5 Dispositif de traction...3816
      3.2.6 Prise de courant...3817
      3.2.7 Déverrouillage de la porte et des fenêtres...3817
      3.2.8 Avertisseur de recul...3817
      3.2.9 Fusibles...3818
      3.2.10 Fusibles à action retardée...3820
      3.2.11 Réglage du système de chauffage et d'aération...3821
      3.2.12 Climatiseur...3822
    3.3 Opération...3824
      3.3.1 Contrôles avant le démarrage...3824
        Contrôle visuel...3824
        Contrôles avant le démarrage...3827
        Réglages avant le démarrage...3837
      3.3.2 Démarrage du moteur...3841
        Plage de température ambiante pour le travail et le stockage...3842
        Contrôle après le démarrage...3843
      3.3.3 Rouler avec l'engin...3844
        Démarrage...3844
        Limitation de la vitesse maximale...3845
      3.3.4 Changement du sens de marche...3847
      3.3.5 Utilisation du volant...3848
      3.3.6 Freins...3849
        Enclenchement du frein de stationnement...3849
        Désenclenchement du frein de stationnement...3849
        Freinage au moyen du frein de service...3849
        En cas de panne du frein de service...3850
        Freinage lors du déplacement en pente...3850
      3.3.7 Arrêt et stationnement de l'engin...3851
      3.3.8 Commande de l'outil de travail...3852
        Levier multifonctions...3852
      3.3.9 Return to dig (Réglage du positionneur de godet)...3853
      3.3.10 Travailler avec la chargeuse sur roues...3854
        Travailler en ménageant les pneumatiques...3854
        Activation du blocage de différentiel 100%...3855
        Chargement...3856
        Chargement de matériau...3856
        Excavation...3858
        Nivelage...3859
        Transport...3860
        Travaux de déchargement...3861
        Travaux effectués avec le porte-fourche...3862
      3.3.11 Précautions durant le travail...3864
        Hauteur d'eau maximale autorisée...3864
        Prudence sur la neige...3864
        Déversement sur des pentes abruptes...3864
        Travail à proximité de lignes à haute tension...3864
        Travail sur des talus...3864
        Travail sur les terrains meubles...3864
        En cas de panne du frein de service...3864
        Précautions lors du déplacement en montée ou en descente...3865
        Précautions durant le déplacement...3865
      3.3.12 Réglage des outils de travail...3866
        Sélection de l'outil de travail...3866
        Installation de l'outil de travail...3866
        Dépose de l'outil de travail...3869
        Dépose du godet multifonctions...3870
        Indicateur de niveau du godet...3870
      3.3.13 Arrêt du moteur...3871
      3.3.14 Contrôles après l'arrêt du moteur...3871
      3.3.15 Verrouillage...3871
      3.3.16 Manipulation des pneumatiques...3872
        Précautions concernant les pneumatiques...3872
        Pression des pneumatiques...3872
        Pneus standard...3873
    3.4 Transport...3874
      3.4.1 Procédure de transport...3874
        Assurer la stabilité de la machine...3874
      3.4.2 Chargement et déchargement de l'engin...3874
        Chargement de l'engin...3875
        Sécurisation de l'engin...3876
        Déchargement de l'engin...3878
      3.4.3 Levage de l'engin...3879
        Procédure de levage...3882
    3.5 Utilisation par temps froid...3883
      3.5.1 Précautions pour l'utilisation par temps froid...3883
      3.5.2 Précautions à prendre après le travail...3884
      3.5.3 Après l'hiver...3884
    3.6 Remisage à long terme...3885
      3.6.1 Avant le remisage...3885
      3.6.2 Durant le remisage...3886
      3.6.3 Après le remisage...3886
    3.7 Manipulation d'engins équipés du système KOMTRAX...3887
      3.7.1 Précautions de base...3887
    3.8 Lecture des codes d'erreur...3889
      3.8.1 Réglage du moniteur...3890
  4. Recherche et élimination des pannes...3892
    4.1 Remorquage de l'engin...3893
    4.2 Démarrage du moteur à l'aide de câbles de démarrage...3897
    4.3 En cas de puissance de freinage insuffisante...3900
      4.3.1 Contrôle du frein de service...3900
      4.3.2 Contrôle du frein de stationnement...3900
    4.4 Direction de secours...3901
    4.5 Abaissement de secours...3902
    4.6 Autres pannes...3903
      4.6.1 Système électrique...3903
      4.6.2 Moteur...3904
      4.6.3 Système hydraulique...3907
      4.6.4 Freins...3909
      4.6.5 Direction...3910
      4.6.6 Essieux...3910
      4.6.7 Cabine de l'opérateur...3910
  5. Maintenance...3912
    5.1 Guide pour l'entretien...3913
      5.1.1 Relèvement de la cabine de l'opérateur...3914
      5.1.2 Abaissement de la cabine de l'opérateur...3916
    5.2 Instructions générales d'entretien...3921
      5.2.1 Indications concernant les lubrifiants/carburants/matières consommables...3922
        Huile...3922
        Carburant...3923
        Liquide de refroidissement...3924
        Graisse...3925
        Stockage d'huile et de carburant...3925
        Filtres...3926
        Huile hydraulique et lubrifiants biodégradables...3926
      5.2.2 Généralités concernant le système électrique...3927
    5.3 Liste des pièces d'usure...3928
      5.3.1 Liste des pièces d'usure...3928
    5.4 Lubrifiant / carburant / matière consommable et capacités de remplissage...3929
      5.4.1 Tableau de lubrification...3929
      5.4.2 Marques recommandées, qualité recommandée pour les produits autres que l'huile d'origine KOMATSU...3932
    5.5 Outillage...3933
      5.5.1 Outillage requis...3933
    5.6 Remplacement périodique des pièces essentielles à la sécurité...3934
    5.7 Plan de maintenance...3935
    5.8 Procédure d'entretien...3937
      5.8.1 Contrôles avant le démarrage...3937
      5.8.2 Si nécessaire...3938
        Contrôle du climatiseur...3938
        Contrôle du niveau du liquide lave-glace - remplissage...3940
        Batterie - charge de la batterie intégrée...3940
        Nettoyage de la grille à air...3941
        Nettoyage des lamelles de refroidissement...3941
      5.8.3 Premier entretien après 50 heures...3942
        Système hydraulique - remplacement de l'élément du filtre...3942
        Ecrous de roue - contrôle, resserrage...3942
        Graissage - essieu arrière...3943
      5.8.4 Premier entretien après 250 heures...3944
        Essieux avant et arrière - changement d'huile...3944
        Boîte de transfert - changement d'huile...3944
        Jeu des soupapes - contrôle et réglage...3944
      5.8.5 Entretien toutes les 10 heures...3945
        Graissage - joint d'articulation...3945
      5.8.6 Entretien toutes les 50 heures...3946
        Batterie - contrôle du niveau d'acide...3946
        Graissage - outil de travail...3947
      5.8.7 Entretien toutes les 250 heures...3949
        Frein de service - contrôle des garnitures de frein...3949
        Courroie trapézoïdale de l'alternateur - contrôle de la tension et réglage...3950
        Elément du filtre à air - contrôle, nettoyage ou remplacement...3951
        Graissage - vérin de direction...3954
        Graissage - essieu arrière...3955
        Ecrous de roue - contrôle, resserrage...3956
      5.8.8 Entretien toutes les 500 heures...3957
        Pompe manuelle - contrôle du niveau d’huile...3957
        Frein de service - contrôle des garnitures et des disques de freins, contrôle du niveau d'huile...3958
        Moteur - changement d'huile...3959
        Remplacement de la cartouche du filtre à huile...3960
        Filtre à carburant - remplacement de la cartouche...3961
        Purge du système de carburant...3963
        Remplacement de l'élément du filtre à air, remplacement du filtre de sécurité...3964
        Chauffage/climatiseur - nettoyage/remplacement du tissu filtrant, nettoyage du condensateur...3965
        Contrôle de la pression de gaz de l'accumulateur de pression pour le levier multifonctions...3966
        Accumulateur de pression de l'E.C.S.S. - contrôle de la pression de gaz...3966
        Essieux avant et arrière - contrôle du niveau d'huile...3967
        Boîte de transfert - contrôle du niveau d'huile, remplissage...3968
      5.8.9 Entretien toutes les 1000 heures...3969
        Courroie trapézoïdale de l'alternateur - contrôle de la tension et réglage...3969
        Frein de service - contrôle, changement de l'huile de frein...3970
        Pressions dans les circuits - contrôle et réglage...3970
        Système hydraulique - remplacement du filtre de purge/aération...3971
        Système hydraulique - remplacement de l'élément du filtre...3972
      5.8.10 Entretien toutes les 1500 heures...3973
        Essieux avant et arrière - changement d'huile...3973
        Boîte de transfert - changement d'huile...3975
      5.8.11 Entretien toutes les 2000 heures...3976
        Circuit de refroidissement - changement du liquide de refroidissement et nettoyage du circuit...3976
        Jeu des soupapes - contrôle et réglage...3979
        Système hydraulique - changement de l'huile hydraulique...3980
        Contrôle de la pompe à carburant...3982
        Flexibles de carburant et d'eau de refroidissement - contrôle, remplacement/ renouvellement si nécessaire...3982
        Contrôle de la pompe à eau...3982
      5.8.12 Entretien toutes les 4000 heures...3983
        Graissage - arbre de transmission...3983
  6. Caractéristiques techniques...3984
    6.1 Caractéristiques techniques...3985
      6.1.1 WA65-6...3985
      6.1.2 WA70-6...3985
      6.1.3 WA80-6...3986
      6.1.4 WA90-6...3986
      6.1.5 WA100M-6...3987
    6.2 Niveaux d'émissions sonores...3988
    6.3 Niveau de vibration...3989
    6.4 Valeurs limite pour le déplacement en pente...3991
  7. Accessoires, options...3992
    7.1 E.C.S.S...3993
      7.1.1 Structure et fonctionnement de l'E.C.S.S...3993
      7.1.2 Mesures de précaution lors de l'enclenchement de l'E.C.S.S...3993
      7.1.3 Utilisation de l'E.C.S.S...3994
        Activation de l'E.C.S.S...3994
        Désactivation de l'E.C.S.S...3994
      7.1.4 Précautions concernant la manipulation de l'accumulateur de pression...3994
    7.2 Témoin de contrôle de position du godet...3995
    7.3 Dispositif de graissage centralisé...3996
      7.3.1 Fonctionnement du dispositif de graissage centralisé...3996
      7.3.2 Console d'affichage et de commande...3996
        Affichage DEL...3997
        Touches...3997
      7.3.3 Modifier l'intervalle et la durée du graissage...3998
    7.4 Levier multifonctions avec 3ème circuit de commande...3999
      7.4.1 Fonctionnement du commutateur...3999
  8. Index...4002
    8.1 Index...4003
  9. Notes...4008
 
Komatsu WA65, WA70, WA80, WA90, WA100M Wheel Loaders Repair Service Manual

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