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KOMATSU WA75-3 FLEET WHEEL LOADER SHOP MANUAL VEBM310100 – PDF DOWNLOAD
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Description
KOMATSU WA75-3 FLEET WHEEL LOADER SHOP MANUAL VEBM310100 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA75-3 FLEET WHEEL LOADER SHOP MANUAL VEBM310100 – PDF DOWNLOAD
Language : English
Pages : 252
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WA75-3 FLEET WHEEL LOADER SHOP MANUAL VEBM310100 – PDF DOWNLOAD
Contents................................................................................................................ 2 00 safety 00-3.......................................................................................................... 2 01 general 01-1......................................................................................................... 2 10 structure and function 10-1.......................................................................................... 2 20 testing and adjusting 20-1........................................................................................... 2 30 Disassembly and assembly 30-1........................................................................................ 2 90 appendix 90-1........................................................................................................ 2 SAFETY.................................................................................................................. 3 Safety notice....................................................................................................... 4 1. Before carrying out any greasing or repairs, read all the precautions given on the decals whic............... 4 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work c........... 4 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. W........... 4 4. When carrying out any operation with two or more workers, always agree on the operating proced........... 4 5. Keep all tools in good condition and learn the correct way to use them................................... 5 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools a........... 5 Preparations for work........................................................................................... 5 1. Before adding oil or making any repairs, park the machine on hard, level ground, and block the........... 5 2. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground an....... 5 3. When disassembling or assembling, support the machine with blocks, jacks or stands before star....... 5 4. Remove all mud and oil from the steps or other places used to get on and off the machine. Alwa....... 5 Precautions during work......................................................................................... 6 1. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before........... 6 2. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen the....... 6 3. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get....... 6 4. Before starting work, remove the leads from the battery. Always remove the lead from the negat....... 6 5. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hook....... 6 6. When removing covers which are under internal pressure or under pressure from a spring, always....... 6 7. When removing components, be careful not to break or damage the wiring. Damaged wiring may cau....... 6 8. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto th....... 6 9. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of g....... 6 10. Be sure to assemble all parts again in their original places........................................ 6 11. When installing high pressure hoses, make sure that they are not twisted............................ 7 12. When aligning two holes, never insert your fingers or hand. Be careful not to get your finger....... 7 13. When assembling or installing parts, always use the specified tightening torques. When instal....... 7 Foreword............................................................................................................ 8 General......................................................................................................... 8 Structure and function.......................................................................................... 8 Testing and adjusting........................................................................................... 8 Disassembly and assembly........................................................................................ 8 Maintenance standard............................................................................................ 8 How to read the shop manual......................................................................................... 9 Volumes......................................................................................................... 9 Distribution and updating....................................................................................... 9 Filing method................................................................................................... 9 1. See the page number on the bottom of the page. File the pages in correct order........................... 9 2. Following examples show how to read the page number.................................................. 9 3. Additional pages: Additional pages are indicated by a point (.) and number after the page numb....... 9 Symbols......................................................................................................... 10 Hoisting instructions............................................................................................... 11 1. Check for removal of all bolts fastening the part to the relative parts...................................... 11 2. Check for existence of another part causing interference with the part to be removed..................... 11 Wire ropes.................................................................................................. 11 1. Use adequate ropes depending on the weight of parts to be hoisted, refering to the table below:.............. 11 2. Sling wire ropes from the middle portion of the hook..................................................... 12 3. Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically ........... 12 4. Do not sling a heavy load with ropes forming a wide hanging angle from the hook.......................... 12 GENERAL............................................................................................................. 13 01.................................................................................................................. 13 Dimensions, weights and operating data.................................................................................. 15 Specifications.......................................................................................................... 16 Weight table............................................................................................................ 18 Lubricants and operating mediums........................................................................................ 19 Basic procedures of maintenance......................................................................................... 20 Oil................................................................................................................. 20 Fuel................................................................................................................ 20 Coolant............................................................................................................. 21 Grease.............................................................................................................. 21 Storing oil and fuel................................................................................................ 21 Filters............................................................................................................. 22 Biodegradable hydraulic oils and lubricants......................................................................... 22 Outline of electric system.......................................................................................... 22 Torque list – screws and nuts........................................................................................... 23 STRUCTURE AND FUNCTION.................................................................................................. 25 Powertrain.......................................................................................................... 27 Outline......................................................................................................... 27 Closed circuit...................................................................................................... 28 Installation step by step....................................................................................... 28 Outline........................................................................................................ 28 Hydraulic drive system.............................................................................................. 29 Variable displacement pump.......................................................................................... 30 Function........................................................................................................ 32 Regulating valve................................................................................................ 33 Charge pressure limiting valve.................................................................................. 33 Control cylinder................................................................................................ 34 4/3 Way valve with direction control solenoids.................................................................. 34 Pressure cut-off valve.......................................................................................... 35 Safety-/charge valve............................................................................................ 35 Towing.......................................................................................................... 36 Function.................................................................................................... 36 Valve Function.............................................................................................. 36 Variable displacement motor......................................................................................... 37 Function........................................................................................................ 38 Drive shaft......................................................................................................... 39 Description..................................................................................................... 39 Axle mounting – front and rear axle................................................................................. 40 Tightening torque:.............................................................................................. 40 Front axle with drum brake.......................................................................................... 41 Rear axle with distributor box...................................................................................... 42 Distributor box..................................................................................................... 43 Description..................................................................................................... 43 Limited slip differential (locking value 25%), front and rear axle.................................................. 44 Function........................................................................................................ 45 Operation....................................................................................................... 45 Wheel hub, front and rear axle...................................................................................... 46 Service and parking brake with slack adjuster, front axle........................................................... 47 Automatical slack adjuster...................................................................................... 47 Service and parking brake....................................................................................... 48 Service brake............................................................................................... 48 Function.................................................................................................... 48 Parking brake............................................................................................... 48 Function.................................................................................................... 48 Automatical adjuster............................................................................................ 49 Description................................................................................................. 49 Function.................................................................................................... 49 Sevice and parking brake circuit.................................................................................... 50 Inch-brake valve.................................................................................................... 51 Function........................................................................................................ 51 Steering articulation joint......................................................................................... 52 Description..................................................................................................... 52 Steering system..................................................................................................... 53 Hydraulic circuit diagram....................................................................................... 53 Priority valve port identification.......................................................................... 53 Priority valve.................................................................................................. 54 Outline..................................................................................................... 54 Orbit-roll-valve................................................................................................ 55 Outline..................................................................................................... 55 Structure................................................................................................... 55 Steering relief valve........................................................................................... 56 Function.................................................................................................... 56 Work equipment hydraulic............................................................................................ 58 Travel, steerig and work hydraulics............................................................................. 58 Travel, steering and work hydraulics........................................................................ 59 T........................................................................................................... 59 PPC-Valve........................................................................................................... 60 PPC-valve port identification................................................................................... 60 Operation of PPC-valve.......................................................................................... 61 Function.................................................................................................... 61 Operation................................................................................................... 61 Servo pressure regulating valve................................................................................. 62 Function.................................................................................................... 62 Operation................................................................................................... 62 Main control valve.................................................................................................. 63 Main control valve port identification.......................................................................... 63 Control circuit for tilt-in / tilt-out (cross section).......................................................... 64 Connection identification on the main control valve......................................................... 64 Pressure regulating valve....................................................................................... 65 Function.................................................................................................... 65 Shock-anticavitation valve...................................................................................... 65 Function.................................................................................................... 65 Anticavitation valve............................................................................................ 66 Function.................................................................................................... 66 Lift cylinder....................................................................................................... 67 Dimensions...................................................................................................... 67 Tightening torque............................................................................................... 67 Pressures....................................................................................................... 67 Dump cylinder....................................................................................................... 68 Dimensions...................................................................................................... 68 Tightening torque............................................................................................... 68 Pressures....................................................................................................... 68 Steering cylinder................................................................................................... 69 Dimensions...................................................................................................... 69 Tightening torque............................................................................................... 69 Pressures....................................................................................................... 69 Lifting frame with quick-coupler.................................................................................... 70 Quick-coupler....................................................................................................... 71 Function........................................................................................................ 71 Bucket positioner................................................................................................... 72 Function........................................................................................................ 73 Operation of proximity switch................................................................................... 73 Adjusting the bucket positioner................................................................................. 74 1. Lower the bucket to the ground and set the bucket to the desired digging angle. Set the bucket........... 74 2. Loosen two bolts (1) and adjust mounting bracket (4) of the proximity switch so that the rear ....... 74 3. Loosen two nuts (5) of the proximity switch and adjust to make a clearance of 6 to 8 mm (0.12 ....... 74 4. After the adjustment, start the engine and raise the lift arm. Operate the bucket lever to the....... 74 Action of proximity switch.............................................................................. 74 Monitor display..................................................................................................... 75 Sensors............................................................................................................. 76 Engine oil pressure sensor...................................................................................... 76 Function.................................................................................................... 76 Fuel level sensor............................................................................................... 77 Function.................................................................................................... 77 Engine coolant temperature sensor............................................................................... 78 Function.................................................................................................... 78 Brake oil reservoir sensor...................................................................................... 79 Ribbon heater temperature sender unit........................................................................... 80 Ribbon heater....................................................................................................... 81 Function........................................................................................................ 81 Operation....................................................................................................... 81 Engine stop/start/preheating circuit................................................................................ 82 Engine stop/ start/ preheating circuit.......................................................................... 83 Engine start.................................................................................................... 83 Electrics........................................................................................................... 84 Fuses (1)....................................................................................................... 84 Relais (2)...................................................................................................... 84 Engine room..................................................................................................... 85 Slow-blowing fuses (1)...................................................................................... 85 Relais (2).................................................................................................. 85 Wiring diagrams..................................................................................................... 87 Wiring diagram – Fig. 1......................................................................................... 88 Wiring diagram – Fig. 2......................................................................................... 91 Wiring diagram – Fig. 3......................................................................................... 92 Wiring diagram – Fig. 4......................................................................................... 95 Wiring diagram – Fig. 5......................................................................................... 96 TESTING AND ADJUSTING................................................................................................... 99 1. The standard values in the table are the values for a new machine and are given as reference v...................100 2. The permissible values given in the table are values estimated based on the results of various...............100 3. These standard values do not form a basis for judging claims.................................................100 Standard value table for engine.....................................................................................101 Standard value table for chassis....................................................................................102 Standard value table for chassis................................................................................103 Standard value table for chassis................................................................................104 Standard value table for electrical parts...........................................................................105 Test certificate....................................................................................................106 Valve clearance, testing and adjusting..............................................................................107 1. Turn the engine until the cylinder that is to be adjusted is at top dead center. In this posit...............107 2. Remove the valve cover and release the locknut (2) and the adjusting screw (1). Check that the...........107 3. Use a feeler gauge to test the valve clearance...........................................................107 4. Use a screwdriver to hold the adjusting screw (1) in position and tighten the locknut (2). The...........107 5. Re-test after tightening the locknut. Make sure that the feeler gauge has a slight resistance,...........107 6. Slightly oil the valve cap, rocker and also the adjusting screw..........................................107 Engine compression test.............................................................................................108 1. Remove the injectors.........................................................................................108 2. Turn the engine with the starter and the injection pump in the stop position before fitting th...........108 3. Install the compression tester on the adapter............................................................108 4. Using the procedure in step 2, turn the engine over using the starter motor. Note the max. sta...........108 Injection nozzle pressure...........................................................................................109 1. Remove the injection pipes and close the connections. Remove the overflow lines..............................109 2. Remove carbon deposit at the nozzle hole thoroughly......................................................109 3. Connect the injection valve (1) to the high pressure pipe (2) of the nozzle tester (3)...................109 4. Operate the lever (4) slowly and read the pressure at the moment when the injection from the n...........109 5. If the measured injection pressure is too small, replace the pressure adjusting shim (5) with ...........109 Fuel injection timing...............................................................................................110 1. Set the engine ready for starting. (Complete air bleeding from the fuel line.)...............................110 2. Disconnect the high pressure tube for the No, 1 cylinder on the fuel upmp side (5). (Do not re...........110 3. Turning the pulley (3), turn the engine clockwise. Stop turning when fuel comes out at the del...........110 4. Wipe the cut-off-valve (5) clean.........................................................................110 5. Turn the pulley (3) in the opposite direction to approx. 20 before the top..............................110 6. Slowly turn the pulley (3) clockwise until fuel comes out at the delivery valve (5)......................110 7. If the injection begin is not correct, adjust by releasing the locknuts (6) and turning the in...........110 8. Repeat steps 3. to 5. a few times........................................................................110 Fan belt............................................................................................................111 1. Press the fan belt in with a finger (98N, 10 kg), between the generator (2) and water pump (1)...............111 2. Adjusting the fan belt tension...........................................................................111 Engine RPM..........................................................................................................112 1. Fit the RPM tester to the engine (3).........................................................................112 2. When the engine has reached working temperature slowly rise the RPM......................................112 3. If the RPM is not at correct adjust use the adjusting screws (see test certificate)......................112 RPM-dependant drive take-up.........................................................................................113 Testing.........................................................................................................113 1. Fit the RPM tester to the engine (1).........................................................................113 2. Release the parking brake and select FORWARD.............................................................113 3. Press the accelerator pedal and increase the engine RPM slowly...........................................113 4. Note the indicated engine speed, when the machine just starts to move forward............................113 Adjusting...................................................................................................113 1. Release the locknut (4) on the regulating valve (2) for RPM dependant. Adjust the setting with...............113 Engine stall torque RPM.............................................................................................114 1. Before testing, connect the RPM tester to the engine (1).....................................................114 Engine stall torque RPM, test with the hydrostatic drive.......................................................114 1. Remove the brake pedal linkage (2) from the inch valve operating lever (3)...............................114 2. Start the engine and run in low idle.................................................................114 3. Release the parking brake............................................................................114 4. Select FORWARD.......................................................................................114 5. Press the brake pedal and slowly rise the engine RPM to max..........................................115 6. Note the maximum engine rpm when the engine is under hydrostatic load................................115 Engine stall torque RPM, test with the hydrostatic drive and working hydraulics................................115 1. Move the boom lift hydraulic control lever and lift the boom until the main pressure relief va...........115 2. Note the engine max. RPM in this condition, with hydrostatic drive and boom rise.....................115 Feed pump and servo oil pressure....................................................................................116 Testing.........................................................................................................116 1. Connect a pressure testing gauge (60 bar) to the testing point (1)...........................................116 2. Run the engine at high idle RPM..........................................................................116 3. Note the pressure shown on the pressure testing gauge. (see test certificate)............................116 Hydraulic pressure cut-off..........................................................................................117 Testing.........................................................................................................117 1. Connect a pressure test gauge (test range to 600 bar) to the test connector (1) for FORWARD..................117 2. Block the drive train. Make sure that the wheels can not slip during the test............................117 3. Start the engine and select FORWARD......................................................................117 4. Run the engine to max. RPM and note the pressure shown on the pressure gauge.............................117 5. Connect a pressure test gauge (test range to 600 bar) to the test connector (2) for REVERSE..............117 6. Block the drive train. Make sure that the wheels can not slip during the test............................117 7. Start the engine and select REVERSE......................................................................117 8. Run the engine to max. RPM and note the pressure shown on the pressure gauge.............................117 Adjustment..................................................................................................118 1. Release the locknut (3) on cut-off valve (1). Adjust the pressure on the adjusting screw (2).................118 Working hydraulic pressure..........................................................................................119 Testing.........................................................................................................119 1. Start the engine and run at full RPM.........................................................................119 2. Connect a pressure testing gauge (testing range 250 bar) to the test point (2)...........................119 3. Move the hydraulic control lever to LIFT, and hold in the end position so that the main pressu...........119 4. Note the pressure on the pressure testing gauge..........................................................119 Adjusting...................................................................................................119 1. Release the locknut (5) on the main pressure release valve (3). Adjust the pressure using the ...............119 Steering oil pressure...............................................................................................120 1. Connect a pressure testing gauge (testing range 250 bar) to the pressure test point (1)......................120 2. Fit the steering safety rod in the articulation joint so that the machine can not be steered.............120 3. Start the engine and run at full RPM.....................................................................120 4. Turn the steering wheel to the right until the end position is reached and hold..........................120 5. Note the pressure shown on the pressure testing gauge....................................................120 Operating time for steering wheel...................................................................................121 Testing.........................................................................................................121 1. tart the engine, raise the bucket approx. 400 mm.............................................................121 2. Operate the steering wheel to the end of its stroke to turn the machine to the left or right.............121 3. Measure the time to operate the steering wheel to the end of the stroke to the right (left)..............121 Operating force of steering wheel...................................................................................122 Testing.........................................................................................................122 1. Install push-pull scale to the steering wheel knob...........................................................122 2. Start the engine, raise the bucket approx. 400 mm........................................................122 3. Pull push-pull scale in the tangential direction and measure the value when the steering wheel...........122 Brake...............................................................................................................123 Brake lining, wear test.........................................................................................123 1. Remove plug (1) on the left and right side of the brake carrier..........................................123 2. Check thickness (S) of the brake pads................................................................123 Bleeding the brake system.......................................................................................124 Air bleeding prozess........................................................................................124 1. Open the maintenance cover in the cabin floor............................................................124 2. Remove the cap from the air bleeding valve at the main brake cylinder under the cabin floor..........124 3. Connect the hose to the bleed valve and put the other end of the hose into a seperate container......124 4. Operate the brake pedal and open the bleed valve to bleed the air from the system. Before the .......124 5. If the brake fluid flow is free from air bubbles, close the bleed valve, while the brake pedal.......124 6. Then remove the cap from the bleed valves (1) on the axles and repeat steps 3. - 5...................124 7. Confirm the brake performance after air bleeding. Put the caps back to the bleed valves..............124 Inch valve – basic adjustment.......................................................................................125 Adjustment A....................................................................................................125 1. Slacken the fork (4) on the brake rod of the brake pedal (1).................................................125 2. Release the locknut (5) and turn the brake rod until the distance A: 127 ± 1.5 mm is correct.............125 3. Install the fork (4) on the brake rod to the brake pedal (1).............................................125 Adjustment B................................................................................................125 1. Release the locknut (3) and turn the adjusting nut (2) to move the pedal angle...............................125 2. Tighten the locknut (3) and check the pedal angle adjustment B...........................................125 Adjustment C................................................................................................125 1. Remove the fork of rod (9) from the lever (7)................................................................125 2. Release the locknut (8) and turn the rod (9) until the distance C is correct.............................125 3. Check the clearance between the stop pin (6) and the pin of the housing on the inch valve. The...........125 4. Install the fork of rod (9) in the center hole of the lever (7)..........................................125 Brake efficiency....................................................................................................126 Measuring the stopping distance.................................................................................126 Testing.....................................................................................................126 1. Start the engine and drive off...........................................................................126 2. Set the speed at 20 km/h.............................................................................126 3. Using the correct force, press the brakes when passing the point of start with 20 km/h...............126 4. Measure the distance taken to stop from the point of starting to brake...............................126 Parking brake efficiency............................................................................................127 Testing.........................................................................................................127 1. Start the engine and set the machine straight ahead. Drive the machine up the 25% gradient...................127 2. Use the foot brake to stop the machine and hold..........................................................127 3. Lower the bucket.........................................................................................127 4. Put the forward/ reverse lever in NEUTRAL................................................................127 5. Stop the engine..........................................................................................127 6. Apply the parking brake, slowly release the foot brake. The machine should not move......................127 Travel speed........................................................................................................128 Testing.........................................................................................................128 1. Start the engine and drive off...............................................................................128 2. Select the speed range 20 km/h...........................................................................128 3. Drive the machine at max. speed over the complete test run...............................................128 4. Start the stop watch when passing point "1" and stop the stop watch when passing point "2"...............128 5. Carry the stopped time (Y) and the driven distance (X) between point "1" and "2" over in the f...........128 DISASSEMBLY AND ASSEMBLY................................................................................................129 Comments............................................................................................................131 Weight dimensions/fluid capacities..............................................................................131 Starter assembly....................................................................................................132 Removal of starter assembly.....................................................................................132 1. Electrical cables........................................................................................132 2. Fastening screws 1.......................................................................................132 Installation of starter assembly................................................................................132 Alternator assembly.................................................................................................133 Removal of alternator assembly..................................................................................133 1. Electrical connections...................................................................................133 2. Support and belt drive...................................................................................133 Installation of alternator assembly.............................................................................134 Water pump assembly.................................................................................................135 Removal of water pump assembly..................................................................................135 1. Drain the coolant 1......................................................................................135 2. Alternator...............................................................................................135 3. Thermostat...............................................................................................135 4. Lines....................................................................................................135 5. Heater line (option).....................................................................................135 6. Mounting.................................................................................................136 7. Gaskets and washers......................................................................................136 Installation of water pump assembly.............................................................................136 Engine cover assembly...............................................................................................137 Removal of engine cover assembly................................................................................137 1. Preliminary work.........................................................................................137 2. Gas-filled shock absorbers...............................................................................137 3. Engine cover.............................................................................................137 Installation of engine cover assembly...........................................................................137 Engine cover support assembly.......................................................................................138 Removal of engine cover support assembly........................................................................138 1. Insulating mat...........................................................................................138 2. Tank filler pipe.........................................................................................138 3. Exhaust pipe.............................................................................................138 4. Engine cover support.....................................................................................139 Installation of engine cover support assembly...................................................................139 Engine assembly.....................................................................................................140 Removal of engine assembly......................................................................................140 1. Covers...................................................................................................140 2. Draining the coolant 1...................................................................................140 3. Draining the engine oil 2................................................................................140 4. Electrical connections...................................................................................140 5. Air cleaner..............................................................................................141 6. Windscreen wiper reservoir tank..........................................................................141 7. Radiator.................................................................................................141 8. Variable displacement pump/hydraulic pump................................................................142 9. Fuel supply lines........................................................................................142 10. Engine governor.........................................................................................142 11. Exhaust piper...........................................................................................142 12. Engine support..........................................................................................143 13. Variable displacement pump..............................................................................143 14. Clutch..................................................................................................143 15. Engine support..........................................................................................143 16. Fan.....................................................................................................144 17. Support with contact lugs...............................................................................144 Installation of engine assembly.................................................................................145 Clutch assembly.....................................................................................................148 Removal of clutch assembly......................................................................................148 1. Clutch...................................................................................................148 Installation of clutch assembly.................................................................................149 Radiator assembly...................................................................................................150 Removal of radiator assembly....................................................................................150 1. Draining the coolant 1...................................................................................150 2. Draining hydraulic oil from radiator 2...................................................................150 3. Hoses....................................................................................................150 4. Radiator partitioning wall...............................................................................150 5. Fan guard................................................................................................151 6. Mounting.................................................................................................151 Installation of radiator assembly...............................................................................152 Fan and pulley assembly.............................................................................................153 Removal of fan and pulley assembly..............................................................................153 1. Alternator...............................................................................................153 2. Fan......................................................................................................153 Installation of fan and pulley assembly.........................................................................154 Inch brake valve assembly...........................................................................................155 Removal of inch brake valve assembly............................................................................155 1. Hydraulic lines..........................................................................................155 2. Valve lever..............................................................................................155 3. Inch brake valve.........................................................................................155 Installation of inch brake valve assembly.......................................................................156 Priority valve assembly.............................................................................................157 Removal of priority valve assembly..............................................................................157 1. Hydraulic lines..........................................................................................157 2. Mounting.................................................................................................157 Installation of priority valve assembly.........................................................................158 Steering valve assembly.............................................................................................159 Removal of steering valve assembly..............................................................................159 1. Cover....................................................................................................159 2. Hydraulic lines..........................................................................................159 3. Heater (option)..........................................................................................159 4. Steering valve...........................................................................................160 Installation of steering valve assembly.........................................................................160 Counterweight assembly..............................................................................................161 Removal of counterweight assembly...............................................................................161 1. Cover plates.............................................................................................161 2. Rear lights..............................................................................................161 3. Counterweight............................................................................................161 Installation of counterweight assembly..........................................................................162 Main control valve assembly.........................................................................................163 Removal of main control valve assembly..........................................................................163 1. Hydraulic lines..........................................................................................163 2. Main control device......................................................................................163 Installation of main control valve assembly.....................................................................164 Pilot valve assembly................................................................................................165 Removal of pilot valve assembly.................................................................................165 1. Cover....................................................................................................165 2. Electrical connections...................................................................................165 3. Hydraulic lines..........................................................................................165 4. Pilot valve..............................................................................................166 Installation of pilot valve assembly............................................................................166 Monitor assembly....................................................................................................167 Removal of monitor assembly.....................................................................................167 1. Monitor housing..........................................................................................167 2. Electrical connections...................................................................................167 3. Monitor..................................................................................................167 Installation of monitor assembly................................................................................167 Articulated joint assembly..........................................................................................168 Removal of articulated joint assembly...........................................................................168 1. Articulated joint........................................................................................168 Installation of articulated joint assembly......................................................................168 Variable motor assembly.............................................................................................169 Removal of variable motor assembly..............................................................................169 1. Electrical connections...................................................................................169 2. Hydraulic lines..........................................................................................169 3. Variable motor...........................................................................................169 Installation of variable motor assembly.........................................................................170 Rear axle assembly..................................................................................................171 Removal of rear axle assembly...................................................................................171 1. Raising the rear end.....................................................................................171 2. Wheels...................................................................................................171 3. Variable motor...........................................................................................172 4. Axles....................................................................................................172 Installation of rear axle assembly..............................................................................172 Front axle assembly.................................................................................................173 Removal of front axle assembly..................................................................................173 1. Drum brake...............................................................................................173 2. Raising the front end....................................................................................174 3. Wheels...................................................................................................174 4. Axles....................................................................................................174 Installation of front axle assembly.............................................................................175 Wheel hub.......................................................................................................176 1. Fitting of wheel studs...................................................................................176 2. Installation of outer races of taper roller bearings.................................................176 3. Assembling of bearings...............................................................................176 4. Fitting of seal......................................................................................176 Wheel hub onto axle housing.....................................................................................177 Planetary gear..................................................................................................178 Bevel pinion support............................................................................................179 Adjustments of bevel gear set...................................................................................184 Taper roller bearings of differential...........................................................................185 Disassembly of differential.....................................................................................187 Limited slip differential.......................................................................................189 Special tools...................................................................................................190 Disassembly of planetary reduction and axle shaft...............................................................198 Assembling of planetary reduction and axle shaft...............................................................204 Disassembly of bevel pinion.....................................................................................210 Only if necessary...........................................................................................213 Assembly and adjustment of bevel pinion.........................................................................214 Only if it has been removed.................................................................................214 NOTE........................................................................................................214 1. The cavity located on the outer diameter must face upwards...............................................214 2. Check and lubricate the O-ring (20)..................................................................214 HINWEIS.................................................................................................220 Special tools...................................................................................................223 Variable displacement pump assembly.................................................................................229 Removal of variable displacement pump assembly..................................................................229 1. Covers...................................................................................................229 2. Electrical connections...................................................................................229 3. Hydraulic lines..........................................................................................229 4. Variable displacement pump...............................................................................230 Installation of variable displacement pump assembly.............................................................231 Hydraulic pump assembly.............................................................................................232 Removal of hydraulic pump assembly..............................................................................232 1. Covers...................................................................................................232 2. Hydraulic pump...........................................................................................232 Installation of hydraulic pump assembly.........................................................................233 Quick-attach coupler assembly.......................................................................................234 Removal of quick-attach coupler assembly........................................................................234 1. Hydraulic lines..........................................................................................234 2. Rocker arm...............................................................................................234 3. Quick-attach coupler.....................................................................................234 Installation of quick-attach coupler assembly..................................................................235 Steering cylinder assembly..........................................................................................236 Removal of steering cylinder assembly...........................................................................236 1. Hydraulic lines..........................................................................................236 2. Lubricant lines..........................................................................................236 3. Steering cylinder........................................................................................236 Installation of steering cylinder assembly......................................................................237 Lift cylinder assembly..............................................................................................238 Removal of lift cylinder assembly...............................................................................238 1. Hydraulic lines..........................................................................................238 2. Lifting cylinder.........................................................................................238 Installation of lift cylinder assembly..........................................................................239 Dump cylinder assembly..............................................................................................240 Removal of dump cylinder assembly...............................................................................240 1. Hydraulic lines..........................................................................................240 2. Bucket cylinder..........................................................................................240 Installation of dump cylinder assembly..........................................................................241 Replacing of windows in driver’s cab................................................................................242 Preparation work for replacing the front window:................................................................242 Preparation work for replacing the rear window:.................................................................242 Preparation work for replacing the door windows:................................................................242 Preparation work for replacing the side window:.................................................................242 ................................................................................................................242 Tools for reworking tasks:..................................................................................243 Replacing a window:.........................................................................................243 Spare Parts:................................................................................................244 APPENDIX................................................................................................................245 90......................................................................................................................245
DESCRIPTION:
KOMATSU WA75-3 FLEET WHEEL LOADER SHOP MANUAL VEBM310100 – PDF DOWNLOAD
General
This shop manual has been prepared as an aid to improve the quality of repairs by giving the service personnel an accurate understanding of the product and by showing them 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 this section.
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.
S.S 18/12/24
