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Komatsu WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 Wheel Loader Shop Manual – PDF DOWNLOAD
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Komatsu WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 Wheel Loader Shop Manual
Book Code: VEBM950201
SERIAL NUMBER:
WA65-3 HA940051 AND UP
WA65-3 PARALLEL LIFT HA050051 AND UP
WA75-3 HA950051 AND UP
WA85-3 HA960051 AND UP
WA90-3 HA970051 AND UP
WA95-3 HA980051 AND UP
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Description
Komatsu WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA65-3, WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3
Serial Number: HA940051 and up, HA050051 and up, HA950051 and up, HA960051 and up, HA970051 and up, HA980051 and up
Book Code: VEBM950201
Language: English
Pages: 422
File Format: Portable Document Format (PDF)
KOMATSU WA65-3 PARALLEL LIFT, WA75-3, WA85-3, WA90-3, WA95-3 WHEEL LOADER SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 Wheel Loader Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in thissection.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD :
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 Wheel Loader Shop Manual
SAFETY........................................................................................... 7 Safety notice................................................................................ 8 Preparations for work.................................................................... 9 Precautions during work.................................................................. 10 Foreword..................................................................................... 12 How to read the shop manual.................................................................. 13 Volumes.................................................................................. 13 Distribution and updating................................................................ 13 Filing method............................................................................ 13 Symbols.................................................................................. 14 Hoisting instructions........................................................................ 15 GENERAL.......................................................................................... 17 Dimensions, weights and operating data – WA65-3.............................................. 20 Dimensions, weights and operating data – WA65-3 Parallel Lift................................ 21 Specifications – WA65-3/WA65-3 Parallel Lift................................................. 22 Dimensions, weights and operating data – WA75-3.............................................. 25 Specifications – WA75-3...................................................................... 26 Dimensions, weights and operating data – WA85-3.............................................. 29 Specifications – WA85-3...................................................................... 30 Dimensions, weights and operating data – WA90-3.............................................. 33 Specifications – WA90-3...................................................................... 34 Dimensions, weights and operating data – WA95-3.............................................. 37 Specifications – WA95-3...................................................................... 38 Weight table – WA65-3/WA65-3 Parallel Lift................................................... 40 Deviating weights for WA65-3 Parallel Lift.............................................. 40 Weight table – WA75-3/WA85-3................................................................. 41 Weight table – WA90-3/95-3................................................................... 42 Lubricants and operating mediums – WA65-3.................................................... 43 Lubricants and operating mediums – WA75-3/WA85-3............................................. 44 Lubricants and operating mediums – WA90-3/WA95-3............................................. 45 Basic procedures of maintenance.............................................................. 46 Oil...................................................................................... 46 Fuel..................................................................................... 46 Coolant.................................................................................. 47 Grease................................................................................... 47 Storing oil and fuel..................................................................... 47 Filters.................................................................................. 48 Biodegradable hydraulic oils and lubricants.............................................. 48 Outline of electric system............................................................... 48 Torque list – screws and nuts................................................................ 49 STRUCTURE AND FUNCTION........................................................................... 51 Powertrain................................................................................... 53 Closed circuit............................................................................... 54 Hydraulic drive system, 20 km/h – WA65-3 bis WA95-3.......................................... 55 Hydraulic drive system, 30 km/h – WA75-3 bis WA95-3 (option)................................. 56 Variable displacement pump................................................................... 57 Regulating valve......................................................................... 60 Charge pressure limiting valve........................................................... 60 Control cylinder......................................................................... 61 4/3 Way valve with direction control solenoids........................................... 61 Pressure cut-off valve................................................................... 62 Safety-/charge valve..................................................................... 62 Towing................................................................................... 63 Variable displacement motor.................................................................. 64 Drive shaft.................................................................................. 67 Axle mounting – front and rear axle.......................................................... 68 Front axle with drum brake – WA65-3.......................................................... 69 Front axle – WA75-3/WA85-3................................................................... 70 Front axle – WA90-3/WA95-3................................................................... 71 Rear axle with distributor box – WA65-3...................................................... 72 Rear axle with distributor box – WA75-3/WA85-3............................................... 73 Rear axle with distributor box – WA90-3/WA95-3............................................... 74 Distributor box, single stage (20 km/h) – WA65-3/WA75-3/ WA85-3.............................. 75 Distributor box, single stage (20 km/h) – WA90-3/WA95-3...................................... 76 Distributor box, double stage (30 km/h) – WA75-3/WA 85-3/ WA90-3/WA95-3...................... 77 Limited slip differential (locking value 25%), front and rear axle – WA65-3/WA75-3/WA85-3.... 78 Wheel hub, front and rear axle – WA65-3/WA75-3/WA85-3........................................ 80 Service and parking brake with slack adjuster, front axle – WA65-3/WA75-3/WA85-3............. 81 Service and parking brake................................................................ 82 Automatical adjuster..................................................................... 83 Service and parking brake, rear axle – WA75-3/WA85-3......................................... 84 Service and parking brake, rear axle – WA90-3/WA95-3......................................... 86 Sevice and parking brake circuit – WA65-3.................................................... 88 Sevice and parking brake circuit – WA75-3/WA85-3/ WA903/WA95-3.............................. 89 Inch-brake valve............................................................................. 90 Steering articulation joint.................................................................. 91 Steering system.............................................................................. 93 Hydraulic circuit diagram of steering system – WA65-3/WA75-3/WA85-3...................... 93 Hydraulic circuit diagram of steering system – WA90-3/WA95-3............................. 94 Priority valve........................................................................... 95 Orbit-roll-valve......................................................................... 96 Steering relief valve.................................................................... 97 Work equipment hydraulic.....................................................................100 Travel, steering and work hydraulics – WA653............................................100 Travel, steering and work hydraulics – WA653............................................102 Travel, steering and work hydraulics – WA653 Parallel Lift..............................104 Travel, steering and work hydraulics – WA753/WA85-3.....................................106 Travel, steering and work hydraulics – WA753/WA85-3.....................................108 Travel, steering and work hydraulics – WA903/WA95-3.....................................110 Travel, steering and work hydraulics – WA903/WA95-3.....................................112 PPC-Valve....................................................................................114 Operation of PPC-valve...................................................................115 Servo pressure regulating valve..........................................................116 Main control valve...........................................................................118 Control circuit for tilt-in/tilt-out (cross section).....................................119 Pressure regulating valve................................................................120 Shock-anticavitation valve...............................................................120 Anticavitation valve.....................................................................121 Lift cylinder – WA65-3.......................................................................122 Lift cylinder – WA75-3/WA85-3................................................................123 Lift cylinder – WA90-3/WA95-3................................................................124 Dump cylinder – WA65-3.......................................................................125 Dump cylinder – WA65-3 Parallel Lift.........................................................126 Dump cylinder – WA75-3/WA85-3................................................................127 Dump cylinder – WA90/WA95-3..................................................................128 Steering cylinder – WA65-3/WA75-3/WA85-3.....................................................129 Steering cylinder – WA90-3/WA95-3............................................................130 Lifting frame with quick-coupler.............................................................131 Quick-coupler................................................................................132 Lifting with quick-coupler – WA65-3 Parallel Lift...........................................133 Bucket positioner............................................................................135 Function.................................................................................136 Operation of proximity switch............................................................136 Adjusting the bucket positioner..........................................................137 Monitor display..............................................................................139 Sensors......................................................................................140 Engine oil pressure sensor...............................................................140 Fuel level sensor........................................................................141 Engine coolant temperature sensor........................................................142 Brake oil reservoir sensor...............................................................143 Ribbon heater temperature sender unit....................................................144 Ribbon heater................................................................................145 Engine stop/start/preheating circuit.........................................................146 Driver's cab.................................................................................148 Fuses (1)................................................................................148 Relais (2)...............................................................................148 Engine room..............................................................................149 Wiring diagrams..............................................................................151 Wiring diagram – Fig. 1..................................................................152 Wiring diagram – Fig. 2..................................................................155 Wiring diagram – Fig. 3..................................................................156 Wiring diagram – Fig. 4..................................................................159 Air conditioner (option).....................................................................173 Introduction.............................................................................173 Function.................................................................................173 The coolant circuit..................................................................173 The condenser........................................................................176 The vaporizer........................................................................177 The filter dryer.....................................................................178 Design of air conditioner................................................................179 Installation of air conditioner..........................................................180 Safety when handling coolants............................................................181 Operating the air conditioner............................................................183 Maintenance of the air conditioner.......................................................184 Regular maintenance..................................................................185 Instructions for filling.................................................................187 Exchange of magnetic clutch..............................................................190 Exchange of compressor...................................................................191 Troubleshooting..........................................................................193 TESTING AND ADJUSTING............................................................................197 Standard value table for engine – WA65-3.....................................................199 Standard value table for chassis – WA65-3....................................................200 Standard value table for electrical parts – WA65-3...........................................203 Test certificate – WA65-3....................................................................204 Test certificate – WA65-3 Parallel Lift......................................................205 Standard value table for engine – WA75-3/WA85-3..............................................206 Standard value table for chassis – WA75-3/WA85-3.............................................207 Standard value table for electrical parts – WA75-3/WA85-3....................................210 Test certificate – WA75-3....................................................................212 Test certificate – WA85-3....................................................................213 Standard value table for engine – WA90-3/WA95-3..............................................214 Standard value table for chassis – WA90-3/WA95-3.............................................215 Standard value table for electrical parts – WA90-3/WA95-3....................................218 Test certificate WA90-3......................................................................220 Test certificate WA95-3......................................................................221 Valve clearance, testing and adjusting.......................................................223 Engine compression test......................................................................224 Injection nozzle pressure....................................................................225 Fuel injection timing........................................................................226 Fan belt.....................................................................................227 Engine RPM...................................................................................228 RPM-dependant drive take-up..................................................................229 Engine stall torque RPM......................................................................230 Engine stall torque RPM, test with the hydrostatic drive................................230 Engine stall torque RPM, test with the hydrostatic drive and working hydraulics.........231 Feed pump and servo oil pressure.............................................................232 Hydraulic pressure cut-off...................................................................233 Working hydraulic pressure...................................................................235 Steering oil pressure........................................................................236 Operating time for steering wheel............................................................237 Operating force of steering wheel............................................................238 Brake........................................................................................239 Brake lining, wear test – WA65-3.........................................................239 Brake disc, wear test – WA75-3/WA853/ WA90-3/WA95-3.....................................239 Brake disc clearance – WA75-3/WA85-3.....................................................240 Brake disc clearance – WA90-3/WA95-3.....................................................241 Bleeding the brake system – WA65-3 up to WA95-3..........................................242 Inch valve – basic adjustment................................................................243 Parking brake................................................................................244 Basic adjustment – WA75-3 through WA953.................................................244 Brake efficiency.............................................................................245 Measuring the stopping distance..........................................................245 Parking brake efficiency.....................................................................246 Travel speed.................................................................................247 DISASSEMBLY AND ASSEMBLY.........................................................................249 Comments.....................................................................................251 Starter assembly.............................................................................252 Removal of starter assembly..............................................................252 Installation of starter assembly.........................................................253 Alternator assembly..........................................................................254 Removal of alternator assembly...........................................................254 Installation of alternator assembly......................................................255 Water pump assembly..........................................................................256 Removal of water pump assembly...........................................................256 Installation of water pump assembly......................................................258 Engine cover assembly........................................................................259 Removal of engine cover assembly.........................................................259 Installation of engine cover assembly....................................................260 Engine cover support assembly................................................................261 Removal of engine cover support assembly.................................................261 Installation of engine cover support assembly............................................263 Engine assembly..............................................................................264 Removal of engine assembly...............................................................264 Installation of engine assembly..........................................................269 Clutch assembly..............................................................................272 Removal of clutch assembly...............................................................272 Installation of clutch assembly..........................................................273 Radiator assembly............................................................................274 Removal of radiator assembly.............................................................274 Installation of radiator assembly........................................................276 Fan and pulley assembly......................................................................277 Removal of fan and pulley assembly.......................................................277 Installation of fan and pulley assembly..................................................278 Inch brake valve assembly....................................................................279 Removal of inch brake valve assembly.....................................................279 Installation of inch brake valve assembly................................................280 Priority valve assembly......................................................................281 Removal of priority valve assembly.......................................................281 Installation of priority valve assembly..................................................282 Steering valve assembly......................................................................283 Removal of steering valve assembly.......................................................283 Installation of steering valve assembly..................................................285 Counterweight assembly.......................................................................286 Removal of counterweight assembly........................................................286 Installation of counterweight assembly...................................................287 Main control valve assembly..................................................................288 Removal of main control valve assembly...................................................288 Installation of main control valve assembly..............................................289 Pilot valve assembly.........................................................................290 Removal of pilot valve assembly..........................................................290 Installation of pilot valve assembly.....................................................292 Monitor assembly.............................................................................293 Removal of monitor assembly..............................................................293 Installation of monitor assembly.........................................................294 Articulated joint assembly...................................................................295 Removal of articulated joint assembly....................................................295 Installation of articulated joint assembly...............................................296 Variable motor assembly......................................................................297 Removal of variable motor assembly.......................................................297 Installation of variable motor assembly..................................................298 Rear axle assembly...........................................................................299 Removal of rear axle assembly............................................................299 Installation of rear axle assembly.......................................................301 Front axle assembly..........................................................................302 Removal of front axle assembly...........................................................302 Installation of front axle assembly......................................................304 Rear axle (WA65-3/WA75-3/WA85-3).............................................................305 Brake (WA75-3/WA85-3)....................................................................305 Wheel hub................................................................................307 Wheel hub onto axle housing..............................................................308 Planetary gear...........................................................................309 Bevel pinion support.....................................................................310 Adjustments of bevel gear set............................................................315 Taper roller bearings of differential....................................................316 Disassembly of differential..............................................................318 Limited slip differential................................................................320 Special tools............................................................................321 Rear axle (WA90-3/WA95-3)....................................................................329 Checking wear and replacing the braking discs............................................329 Assembling of braking units..............................................................332 Disassembly of planetary reduction and axle shaft........................................335 Assembling of planetary reduction and axle shift........................................341 Disassembly of bevel pinion..............................................................347 Assembly and adjustment of bevel pinion..................................................351 Special tools............................................................................360 Disassembly of mechanic parking brake unit...............................................365 Assembly of mechanic parking brake unit..................................................368 Reduction gear V 30 km/h (WA75-3 through WA95-3).............................................371 Disassembly of integrated reduction gear.................................................371 Assembly of integrated reduction gear....................................................382 Variable displacement pump assembly..........................................................395 Removal of variable displacement pump assembly...........................................395 Installation of variable displacement pump assembly......................................397 Hydraulic pump assembly......................................................................398 Removal of hydraulic pump assembly.......................................................398 Installation of hydraulic pump assembly..................................................399 Quick-attach coupler assembly................................................................400 Removal of quick-attach coupler assembly.................................................400 Installation of quick-attach coupler assembly...........................................401 Steering cylinder assembly...................................................................402 Removal of steering cylinder assembly....................................................402 Installation of steering cylinder assembly...............................................403 Lift cylinder assembly.......................................................................404 Removal of lift cylinder assembly........................................................404 Installation of lift cylinder assembly...................................................405 Dump cylinder assembly.......................................................................406 Removal of dump cylinder assembly........................................................406 Installation of dump cylinder assembly...................................................407 Replacing of windows in driver’s cab.........................................................408 APPENDIX.........................................................................................411
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
3 reviews for Komatsu WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 Wheel Loader Shop Manual – PDF DOWNLOAD
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Zaire Jayce –
ease of use
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So far going smooth..