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Archive for the ‘Komatsu’ Category

komatsu wa115-3 wheel loader repair TROUBLESHOOTING GUIDE

Checks prior to trouble shooting:

  • Check belt tension
  • Check condenser
  • Check condenser blower, rotation direction right
  • Compressor switches on and off
  • Compressor clutch OK
  • Function of air vents OK
  • Coolant level OK (inspection glass)
  • Condensation drain away
  • Air temperature OK

Fault 1. Low pressure too or  high High pressure too high

Cause
Remedy
  • System too full
  • Condenser is dirty or blocked
  • Blower faulty or wrong rotational direc
  • Check filling level
  • Clean condenser or replace
  • Repair blower or replace

Fault 2.  Low pressure too or  high High pressure too high

Cause
Remedy
  • Dryer blockes
  • Faulty expansion valve
  • Compressor faulty
  • Replace dryer
  • Replace expansion valve
  • Replace compressor

Fault 3.  Low and high pressure the same

Cause
Remedy
  • Compressor faulty
  • Check drive belt – belt pulley – magnetic clutch, if all correct, proceed as for “Compressor does not switch on”

Fault 4. Low pressure too low or High pressure normal

Cause
Remedy
  • Faulty expansion valve
  • Dirty or blockes vaporizer
  • Replace expansion valve
  • Clean or replace vaporizer

Fault 5. Low pressure too low or High pressure too low

Cause
Remedy
  • Expansion valve faulty
  • Not enough coolant
  • Insufficient cooling effect only for short time; water in system, expansion valve iced up as a result
  • Dryer or expansion valve partially blocked
  • Vaporizer iced up
  • Thermoswitch not working
  • Replace expansion valve
  • Refill air conditioning system
  • Evacuate system, replace dryer
  • Replace dryer or expansion valve
  • Check the ON and OFF times of the compressor
  • Adjust or replace the thermoswitch

Fault 6. Compressor switches on and off at speed

Cause
Remedy
  • Loose contact in the electric system
  • Coolant pressure too high
  • Check electrical system (air conditioner switch, thermostat)
  • Check air conditioning system pressure and refill if necessary

Read the rest of this entry »

kawasaki mule 610 manual: Engine Removal and Installation

kawasaki mule 610  Engine Removal

1

3

•Disconnect:
Battery Terminal Leads (see Electrical System chapter)

•Remove:
Cargo Bed
Guard Plate (see Frame chapter)
Exhaust Pipe (see Engine Top End chapter)
Torque Converter Case (see Converter System chapter)
Connecting Plate (see Transmission Case in the Trans-mission chapter)
Carburetor (see Fuel System chapter)
Link Bracket [A]
Starter Motor Lead [B] and Connector [C]
Alternator Lead Connector [D]
Ignition Coil Lead Connector [E]
Oil Temperature Sensor Lead Connector [F]
Hose [G]
•Remove:
Engine Mounting Bolts [A] (both sides)
Engine Ground Lead [B]
•Remove:
Engine [A]

kawasaki mule 610 Engine Installation

2

If the transmission case has not been removed, start from the step 2.
Step 1
•Mount the transmission case [A] with the rear axle brack-ets [B] on the swingarm.
•Tighten the rear axle bracket bolts [C] lightly by hand.
Step 2
•Mount the engine [D] on the swingarm.
•Install the engine mount bolts and tighten the nuts [E]
lightly by hand.
•Install the connecting plate [F] to the engine and trans-mission case so that the plate fits to the face shown by spigot joint areas [G].
•Apply a non-permanent locking agent:
Connecting Plate Bolts (M10) [H]
Connecting Plate Bolts (M8) [I]
•Install the washers and tighten the connecting plate bolts(M10 and M8) lightly by hand.
•Install the alignment jig [J] and tighten the bolts.

Special Tool – Alignment Jig: 57001-1631

•Tighten the bolts in the following order.
Torque – Connecting Plate Bolts (M10): 55 N·m (5.6 kgf·m,41 ft·lb)
Connecting Plate Bolts (M8): 28 N·m (2.9 kgf·m,21 ft·lb)
Engine Mounting Bolts and Nuts: 24.5 N·m (2.5kgf·m, 18 ft·lb)
Rear Axle Bracket Bolts: 34 N·m (3.5 kgf·m, 25ft·lb)
•Remove the alignment jig.

4

Komatsu WHEEL LOADER WA500-3H Service Repair Manual SERIAL NUMBER WA500H20051 and up

Instant download Komatsu WHEEL LOADER WA500-3H service repair manual. Including detailed instructions and step-by-step diagrams for all workshop procedures.

Komatsu WHEEL LOADER WA500-3H

This shop manual may contain attachments and optional equipment that are not available in your area.
Please consult your local KOMATSU distributor for those items you may require. Materials and specifications
are subject to change without notice.
 WA500-3H mount the SA6D140E-3 engine.
For details of this engine, see the 140-3 Series Engine Shop Manual.

By using repair guide is usually an low-cost method to keep a person vehicle functioning effectively. Just about every guide gives step-by-step directions in line with the comprehensive disassembly from the machine. It can be this kind of degree of details, as well as hundreds of photographs and designs, in which guide this audience through every support and repair method.

. In depth substeps broaden on mend procedure information
. Paperwork, cautions in addition to alerts through each and every part pinpoint important information.
. Using instructions make suggestions as a result of every single mend procedure detail by detail.
. Bold determine number assist you speedily go with designs with instructions.
. In depth designs, sketches in addition to images make suggestions as a result of every single procedure.
. Bigger inset helps you determine in addition to look at components at length.
. Using table connected with subject matter user friendly to enable you to find the information you may need rapidly.
. This particular guide in addition makes it simple to be able to detect in addition to mend difficulties with your equipment power system. Troubleshooting in addition to power support procedures usually are joined with comprehensive wiring diagrams pertaining to simplicity.

Complete download comes in PDF format which can work under all PC based Windows operating system and Mac also. It saves to your hard-drive and can be burned to CD-ROM. All pages are printable. No need to pay for shipping and wait for the overpriced paper textbook or CD-ROM to arrive via snail mail.

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This Manual Covers:

01 GENERAL01-1

  • SPECIFICATIONS01-3
  • WEIGHT TABLE 01-6
  • FUEL, COOLANT AND LUBRICATNTS 01-7
  • ENGINE OIL 01-8
  • NORMAL OPERATION01-8
  • ARCTIC OPERATION 01-10
  • TRANSMISSION, HYDRAULIC SYSTEM, BRAKE SYSTEM OIL 01-10
  • AXLE OIL01-10
  • GREASE01-11
  • DIESEL FUEL 01-11
  • COOLANT SPECIFICATIONS 01-12
  • GENERAL01-12
  • WATER 01-12
  • ANTIFREEZE01-12
  • SUPPLEMENTAL COOLANT ADDITIVES 01-14

10 STRUCTURE AND FUNCTION10-1

  • GENERAL 10-5
  • RADIATOR AND OIL COOLER 10-7
  • DAMPER 10-8
  • TORQUE CONVERTER AND TRANSMISSION PIPING 10-10
  • HYDRAULIC CIRCUIT FOR POWER TRAIN 10-12
  • HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 10-13
  • TORQUE CONVERTER AND PTO 10-14
  • TRANSMISSION 10-16
  • TRANSMISSION CUTAWAY FOLDOUT 10-18
  • OPERATION OF CLUTCH 10-19
  • FORWARD 1ST 10-20
  • FORWARD 2ND 10-21
  • FORWARD 3RD 10-22
  • FORWARD 4TH 10-23
  • REVERSE 1ST 10-24
  • TRANMISSION CONTROL VALVE 10-26
  • ECMV (ELECTRONIC CONTROL MODULATION VALVE) 10-28
  • OUTLINE OF ECMV 10-30
  • ECMV AND PROPORTIONAL SOLENOID 10-30
  • ECMV AND FILL SWITCH 10-30
  • ACTUATION OF ECMV 10-31
  • MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE 10-34
  • MAIN RELIEF VALVE 10-35
  • TORQUE CONVERTER RELIEF VALVE 10-35
  • LUBRICATING RELIEF VALVE 10-36
  • TORQUE CONVERTER OIL FILTER 10-37
  • PILOT FILTER 10-38
  • TRANSFER 10-39
  • DRIVE SHAFT 10-40
  • CENTER SUPPORT 10-41
  • AXLE 10-42
  • FRONT 10-42
  • REAR 10-43
  • DIFFERENTIAL 10-44
  • NORMAL – (STANDARD) 10-44
  • FRONT 10-44
  • REAR 10-45
  • LIMITED SLIP (OPTION) 10-47
  • FINAL DRIVE 10-50
  • AXLE MOUNT 10-52
  • CENTER HINGE PIN 10-54
  • TIRE AND WHEEL 10-55
  • STEERING PIPING 10-56
  • STEERING COLUMN 10-57
  • STEERING VALVE 10-58
  • DEMAND VALVE OPERATION 10-59
  • STEERING SPOOL AT NEUTRAL 10-59

20 TESTING, ADJUSTING AND TROUBLESHOOTING 20-1

  • 1S2T-A+NDARD VALUE TABLE FOR ENGINE – IN CHASSIS20-5
  • STANDARD VALUE TABLE FOR CHASSIS20-6
  • SKETCHES OF SPECIAL TOOLS20-24
  • ENGINE20-25
  • TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING20-25
  • MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)20-25
  • MEASURING EXHAUST TEMPERATURE 20-25
  • ADJUSTING VALVE CLEARANCE 20-25
  • MEASURING COMPRESSION PRESSURE 20-25
  • MEASURING BLOW-BY PRESSURE 20-25
  • MEASURING OIL PRESSURE 20-25
  • HANDLING EQUIPMENT IN FUEL CIRCUIT20-25
  • RELEASING REMAINING PRESSURE IN FUEL SYSTEM 20-25
  • MEASURING FUEL PRESSURE20-25
  • REDUCED CYLINDER MODE OPERATION 20-25
  • BLEEDING AIR FROM FUEL SYSTEM 20-25
  • CHECK FOR LEAKAGE IN FUEL SYSTEM20-25
  • ADJUSTING SPEED SENSOR20-25
  • TESTING AND ADJUSTING ALTERNATOR BELT TENSION20-25
  • TESTING AND ADJUSTING FAN BELT TENSION20-25
  • HANDLING CONTROLLER HIGH VOLTAGE CIRCUIT 20-25
  • RUN-IN STANDARD 20-25
  • PERFORMANCE TEST STANDARDS 20-25
  • TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 20-25
  • TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)20-25
  • TORQUE CONVERTER STALL SPEEDS20-26
  • AIR CONDITIONER BELT20-26
  • SHIFT LEVERS 20-27
  • OPERATING FORCE OF SPEED LEVER20-27
  • TRAVEL OF SPEED LEVER 20-27
  • ACCELERATOR PEDAL 20-28
  • OPERATING FORCE 20-28
  • OPERATING ANGLE 20-29
  • TORQUE CONVERTER OIL PRESSURE20-30
  • TRANSMISSION OIL PRESSURE20-30
  • TORQUE CONVVERTER AND TRANSMISSION HYDRAULIC CIRCUIT FLUSHING20-34
  • TRANSMISSION VALVE FAILS – MOVING MACHINE 20-36
  • and more

30 DISASSEMBLY AND ASSEMBLY 30-1

  • METHOD OF USING MANUAL30-5
  • PRECAUTIONS DURING OPERATION30-6
  • PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK30-6
  • PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 30-7
  • PRECAUTIONS WHEN COMPLETING THE OPERATIONS 30-8
  • OTHER PRECAUTIONS 30-8
  • SPECIAL TOOL LIST 30-9
  • SKETCHES OF SPECIAL TOOLS30-13
  • ENGINE30-16
  • ALTERNATOR30-16
  • CYLINDER HEAD 30-16
  • ENGINE FRONT SEAL 30-16
  • ENGINE OIL COOLER30-16
  • ENGINE REAR SEAL 30-16
  • FUEL INJECTION PUMP30-16
  • NOZZLE HOLDER 30-16
  • STARTING MOTOR30-16
  • THERMOSTAT30-16
  • TURBOCHARGER 30-16
  • WATER PUMP30-16
  • RADIATOR 30-18
  • REMOVAL30-18
  • INSTALLATION 30-19
  • DAMPER 30-20
  • REMOVAL30-20
  • INSTALLATION 30-21
  • DISASSEMBLY 30-22
  • ASSEMBLY 30-25
  • TORQUE CONVERTER AND TRANSMISSION30-30
  • REMOVAL30-30
  • INSTALLATION 30-33
  • DISCONNECTION 30-34
  • CONNECTION30-34
  • TORQUE CONVERTER30-35
  • DISASSEMBLY 30-35
  • ASSEMBLY 30-39
  • TRANSMISSION30-46
  • DISASSEMBLY 30-46
  • ASSEMBLY 30-63
  • TRANSFER 30-80
  • DISASSEMBLY 30-80
  • ASSEMBLY 30-84
  • PARKING BRAKE 30-89
  • DISASSEMBLY 30-89
  • ASSEMBLY 30-92
  • TRANSMISSION CONTROL VALVE (ECMV) 30-96
  • REMOVAL 30-96
  • and more

40 MAINTENANCE STANDARD 40-1

  • ENGINE MOUNT 40-2
  • TRANSMISSION MOUNT40-4
  • TORQUE CONVERTER CHARGING PUMP 40-6
  • DAMPER40-8
  • TORQUE CONVERTER AND PTO40-10
  • TRANSMISSION40-13
  • TRANSFER 40-18
  • MAIN RELIEF, T C RELIEF VALVE 40-22
  • LUBRICATION RELIEF VALVE 40-24
  • DRIVE SHAFT40-26
  • CENTER SUPPORT40-28
  • DIFFERENTIAL, NORMAL – (STANDARD)40-30
  • FINAL DRIVE 40-34
  • AXLE MOUNT40-36
  • CENTER HINGE PIN 40-38
  • STEERING COLUMN40-42
  • STEERING PUMP40-44
  • STEERING VALVE40-45
  • STEERING CYLINDER MOUNT 40-46
  • BRAKE VALVE 40-48
  • RIGHT 40-48
  • LEFT 40-50
  • SLACK ADJUSTER40-52
  • BRAKE40-54
  • PARKING BRAKE 40-56
  • HYDRAULIC PUMP 40-58
  • SAR(4)-16040-58
  • SWITCH, PPC PUMP 40-60
  • SAR(3)-63 + SAR(1)-28 40-60
  • PPC VALVE40-62
  • FOR BUCKET AND BOOM40-62
  • FOR AUXILIARY ATTACHMENT40-63
  • CUT-OFF VALVE40-64
  • MAIN CONTROL VALVE 40-66
  • 2 SPOOL VALVE40-66
  • 3-SPOOL 40-68
  • HYDRAULIC CYLINDERS40-72
  • BUCKET LINKAGE40-76
  • BUCKET 40-79
  • BUCKET POSITIONER AND BOOM KICK-OUT40-80
  • ROPS CAB40-81
  • and more

90 OTHER90-1

  • ELECTRIACL DIAGRAMS 90-5
  • ECSS WIRING DIAGRAM90-5
  • JOYSTICK STEERING WIRING DIAGRAM 90-7
  • ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 1 of 5)90-9
  • ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 2 of 5) 90-11
  • ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 3 of 5) 90-13
  • ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 4 of 5) 90-15
  • ELECTRICAL CIRCUIT DIAGRAM (SHEET 1) (PART 5 of 5) 90-17
  • ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 1 of 4) 90-19
  • ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 2 of 4) 90-21
  • ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 3 of 4) 90-23
  • ELECTRICAL CIRCUIT DIAGRAM (SHEET 2) (PART 4 of 4) 90-25
  • ENGINE FLOOR HARNESS DIAGRAM 90-27
  • CAB ELECTRICAL DIAGRAM 90-29
  • CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 1 OF 5) 90-31
  • CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 2 OF 5) 90-33
  • CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 3 OF 5) 90-35
  • CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 4 OF 5) 90-37
  • CONNECTOR ARRANGEMENT DIAGRAM (SHEET 1) (PART 5 OF 5) 90-39
  • 3D CONNECTOR ARRANGEMENT DIAGRAM (SHEET 2) (PART 1 OF 2)90-41
  • and more
  • 3D CONNECTOR ARRANGEMENT DIAGRAM (SHEET 2) (PART 2 OF 2)90-43
  • PARKING BRAKE CONTROL DIAGRAM 90-45
  • HYDRAULIC 90-47
  • CIRCUIT DIAGRAM 90-47
  • JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3) 90-49
  • JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 2 OF 3) 90-51
  • JOYSTICK STEERING LINE ASSEMBLY DIAGRAM (PART 3 OF 3) 90-53
  • STEERING LINE ASSEMBLY DIAGRAM (PART 1 OF 3)90-55
  • STEERING LINE ASSEMBLY DIAGRAM (PART 2 OF 3)90-57
  • STEERING LINE ASSEMBLY DIAGRAM (PART 3 OF 3)90-59
  • HYDRAULIC LINE ASSEMBLY (PART 1 OF 3)90-61
  • HYDRAULIC LINE ASSEMBLY (PART 2 OF 3)90-63
  • HYDRAULIC LINE ASSEMBLY (PART 3 OF 3)90-65

Additional information about the service repair manual:

. File Format: PDF
. Compatible: All Versions of Windows & Mac & Linux
. Printable: Yes
. Downloadable: Instant High Speed Download
. Requirements: WinZip & Adobe PDF Reader

Related files:

Komatsu WHEEL LOADER Galeo WA500-6 SERIAL NUMBERS 55001 and up shop repair service manual downlaod

Downlaod Komatsu WHEEL LOADER Galeo WA500-6 SERIAL NUMBERS 55001 and up shop repair service manual 

Machine mode WA500-6

Serial number 55001 and up

DOWNLOAD NOW

This Komatsu WHEEL LOADER Galeo WA500-6 SERIAL NUMBERS 55001 and up shop repair  manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.

Komatsu WHEEL LOADER Galeo WA500-6 SERIAL NUMBERS 55001 and up shop repair service manual downlaod

00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
Engine volume
This section explains the method of reproducing, repairing, and replacing parts.

Service Repair Manual Covers: 

Index and foreword

  • Composition of shop manual
  • Table of contents

Troubleshooting
General information on troubleshooting 2

  • Points to remember when troubleshooting 2
  • Sequence of events in troubleshooting 3
  • Testing before troubleshooting 4
  • Classification and procedures of troubleshooting 5
  • Connection table for connector pin numbers 8
  • T-branch box and T-branch adapter table 31

Troubleshooting 1
Troubleshooting by failure code
(Display of code), Part 1-10

  • Troubleshooting by failure code (Display of code), Part 1 3
  • Failure codes list 3
  • Before carrying out troubleshooting for electrical system 14
  • Information contained in troubleshooting table 16
  • Failure code [1500L0] (TORQFLOW transmission : Double meshing) 18
  • Failure code [15B0NX] (Transmission filter: Clogged) 20
  • Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) 22
  • Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 24
  • Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 26
  • Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 28
  • Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 30
  • Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 32
  • Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 34
  • Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 36
  • Troubleshooting by failure code (Display of code), Part 1 3
  • Failure codes list 3
  • Before carrying out troubleshooting for electrical system 14
  • Information contained in troubleshooting table 16
  • Failure code [1500L0] (TORQFLOW transmission : Double meshing) 18
  • Failure code [15B0NX] (Transmission filter: Clogged) 20
  • Failure code [15SAL1] (ECMV F clutch: When command current is OFF, fill signal is ON) 22
  • Failure code [15SALH] (ECMV F clutch: When command current is ON, fill signal is OFF) 24
  • Failure code [15SBL1] (ECMV R clutch: When command current is OFF, fill signal is ON) 26
  • Failure code [15SBLH] (ECMV R clutch: When command current is ON, fill signal is OFF) 28
  • Failure code [15SEL1] (ECMV 1st clutch: When command current is OFF, fill signal is ON) 30
  • Failure code [15SELH] (ECMV 1st clutch: When command current is ON, fill signal is OFF) 32
  • Failure code [15SFL1] (ECMV 2nd clutch: When command current is OFF, fill signal is ON) 34
  • Failure code [15SFLH] (ECMV 2nd clutch: When command current is ON, fill signal is OFF) 36

Disassembly and assembly

  • General information on disassembly and assembly
  • information on disassembly and assembly 2
  • How to read this manual 2
  • Coating materials list 4
  • Special tool list 7
  • Sketches of special tools11

Engine and cooling system

  • Removal and installation of engine assembly 2
  • Removal and installation of radiator assembly 7
  • Removal and installation of air aftercooler 9
  • Removal and installation of cooling fan and fan motor assembly 10
  • Removal and installation of radiator guard and cooling fan motor assembly 12
  • Removal and installation of fuel tank assembly 15
  • Removal and installation of hood 17

Brake system

Undercarriage and frame

Undercarriage and frame

Work equipment

Cab and its attachments

Electrical system

Hydraulic diagrams and drawings

Electrical diagrams and drawings

 

Related files:

Komatsu WA65-3 WA65-3 Parallel Lift WA75-3 WA85-3 WA90-3 WA95-3 WHEEL LOADER shop Service Manual HA940051 AND UP

That Komatsu WA65-3 WA65-3 Parallel Raise WA75-3 WA85-3 WA90-3 WA95-3 STEERING WHEEL LOADER store repair guide continues to be prepared as an support to boost the grade of maintenance tasks giving this services staff members an exact comprehension of the item in addition to by displaying them the way in which to perform maintenance tasks in addition to make judgements. Make sure you comprehend this material on this guide in addition to utilize it to be able to entire consequence at each and every prospect.

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.

NOTE

The specifications contained in this shop manual are subject to change at any time and without any advance notice. Use the specifications given in the book with the latest date.

Dimensions, weights and operating data – WA65-3

WA65-3

The shop manual Contents:

00 SAFETY

  • Safety notice 00-4
  • Foreword00-8
  • How to read the shop manual 00-9
  • Volumes 00-9
  • Distribution and updating00-9
  • Filing method 00-9
  • Symbols00-10
  • Hoisting instructions 00-11

01 GENERAL

  • Dimensions, weights and operating data – WA65-3 01-4
  • Dimensions, weights and operating data – WA65-3 Parallel Lift 01-5
  • Specifications – WA65-3/WA65-3 Parallel Lift01-6
  • Dimensions, weights and operating data – WA75-3 01-9
  • Specifications – WA75-301-10
  • Dimensions, weights and operating data – WA85-301-13
  • Specifications – WA85-301-14
  • Dimensions, weights and operating data – WA90-301-17
  • Specifications – WA90-301-18
  • Dimensions, weights and operating data – WA95-301-21
  • Specifications – WA95-301-22
  • Weight table – WA65-3/WA65-3 Parallel Lift01-24
  • Deviating weights for WA65-3 Parallel Lift01-24
  • Weight table – WA75-3/WA85-301-25
  • Weight table – WA90-3/95-3 01-26
  • Lubricants and operating mediums – WA65-301-27
  • Lubricants and operating mediums – WA75-3/WA85-3 01-28
  • Lubricants and operating mediums – WA90-3/WA95-3 01-29
  • Basic procedures of maintenance01-30
  • Oil 01-30
  • Fuel 01-30
  • Coolant 01-31
  • Grease 01-31
  • Storing oil and fuel01-31
  • Filters01-32
  • Biodegradable hydraulic oils and lubricants 01-32
  • Outline of electric system 01-32
  • Torque list – screws and nuts01-33

10 STRUCTURE AND FUNCTION 

  • Powertrain10-3 (The engine power is transmitted to the drive axles through a hydrostatic system. The system consists of a variable displacement pump mounted on the engine and a variable displacement motor mounted on the rear axle transmission distribution box. Power is transmitted from the variable displacement motor through the distribution box to the front and rear axles. The front axle is driven through a prop shaft from the distribution box. • Change in the direction driven is achieved by changing the oil flow direction from the variable displacement pump. Changing from forward to reverse is done electrically and can be carried out under power. The force reaction takes place in the variable displacement drive motor. • The power transmitted to the front and rear axles passes through the pinion and crown wheels, through the limited slip differential to the half shafts. • The half shafts drive in turn the hub planetary reduction gears and through the planet carriers the wheels….)
  • Closed circuit 10-4(A hydraulic system is described as closed when the hydraulic fluid is returned from the user direct to the pump. • There is a high pressure and a low pressure side, depending on the direction of load (take-off torque at the user). • The high pressure side is protected by pressure relief valves, which unload to the low pressure side. The hydraulic fluid remains in the circuit. Only the continuous leakage from pump and motor (dependent on operating data) must be replaced. • This fluid is replenished by an integrated auxiliary pump (normally), which delivers a continuous, adequate supply of fluid (boost fluid) via a check valve into the low pressure side of the closed circuit. Any surplus flow of the boost pump which operates in open circuit, is returned via a boost pressure relief valve to the tank. The boosting of the low pressure side enhances the pump operating characteristics…)
  • Hydraulic drive system, 20 km/h – WA65-3 bis WA95-3 10-5
  • Hydraulic drive system, 30 km/h – WA75-3 bis WA95-3 (option)10-6
  • Variable displacement pump 10-7
  • Regulating valve 10-10
  • Charge pressure limiting valve10-10
  • Control cylinder10-11
  • 4/3 Way valve with direction control solenoids10-11
  • Pressure cut-off valve 10-12
  • Safety-/charge valve10-12
  • Towing10-13
  • Variable displacement motor10-14
  • Drive shaft 10-31
  • Axle mounting – front and rear axle10-32
  • Front axle with drum brake – WA65-3 10-33
  • Front axle – WA75-3/WA85-310-34
  • Front axle – WA90-3/WA95-310-35
  • Rear axle with distributor box – WA65-310-36
  • Rear axle with distributor box – WA75-3/WA85-3 10-37
  • Rear axle with distributor box – WA90-3/WA95-3 10-38
  • Distributor box, single stage (20 km/h) – WA65-3/WA75-3/WA85-3 10-39
  • Distributor box, single stage (20 km/h) – WA90-3/WA95-310-40
  • Distributor box, double stage (30 km/h) – WA75-3/WA 85-3/WA90-3/WA95-310-41
  • Limited slip differential (locking value 25%), front and rear axle – WA65-3/WA75-3/WA85-310-42
  • Wheel hub, front and rear axle – WA65-3/WA75-3/WA85-310-44
  • Service and parking brake with slack adjuster, front axle – WA65-3/WA75-3/WA85-3 10-45
  • Service and parking brake 10-46
  • Automatical adjuster10-47
  • Service and parking brake, rear axle – WA75-3/WA85-310-48
  • Service and parking brake, rear axle – WA90-3/WA95-310-50
  • Sevice and parking brake circuit – WA65-310-52
  • Sevice and parking brake circuit – WA75-3/WA85-3/WA90-3/WA95-3 10-53
  • Inch-brake valve10-54
  • Steering articulation joint 10-55
  • Steering system10-61
  • Hydraulic circuit diagram of steering system – WA65-3/WA75-3/WA85-3 10-61
  • Hydraulic circuit diagram of steering system – WA90-3/WA95-310-62
  • Priority valve10-63
  • Orbit-roll-valve 10-64
  • Steering relief valve10-65
  • Work equipment hydraulic10-82
  • Travel, steering and work hydraulics – WA65-3 10-82
  • Travel, steering and work hydraulics – WA65-3 10-84
  • Travel, steering and work hydraulics – WA65-3 Parallel Lift10-86
  • Travel, steering and work hydraulics – WA75-3/WA85-310-88
  • Travel, steering and work hydraulics – WA75-3/WA85-310-90
  • Travel, steering and work hydraulics – WA90-3/WA95-310-92
  • Travel, steering and work hydraulics – WA90-3/WA95-310-94
  • PPC-Valve 10-96
  • Operation of PPC-valve 10-97
  • Servo pressure regulating valve 10-98
  • Main control valve10-100
  • Control circuit for tilt-in/tilt-out
  • (cross section)10-101
  • Pressure regulating valve 10-102
  • Shock-anticavitation valve10-102
  • Anticavitation valve10-103
  • Lift cylinder – WA65-310-104
  • Lift cylinder – WA75-3/WA85-3 10-105
  • Lift cylinder – WA90-3/WA95-3 10-106
  • Dump cylinder – WA65-310-107
  • Dump cylinder – WA65-3 Parallel Lift10-108
  • Dump cylinder – WA75-3/WA85-3 10-109
  • Dump cylinder – WA90/WA95-3 10-110
  • Steering cylinder – WA65-3/WA75-3/WA85-3 10-111
  • Steering cylinder – WA90-3/WA95-3 10-112
  • Lifting frame with quick-coupler10-113
  • Quick-coupler 10-114
  • Lifting with quick-coupler – WA65-3 Parallel Lift 10-115
  • Bucket positioner10-117
  • Function10-118
  • Operation of proximity switch10-118
  • Adjusting the bucket positioner 10-119
  • Monitor display10-127
  • Sensors10-128
  • Engine oil pressure sensor10-128
  • Fuel level sensor10-129
  • Engine coolant temperature sensor 10-130
  • Brake oil reservoir sensor 10-131
  • Ribbon heater temperature sender unit10-132
  • Ribbon heater 10-133
  • Engine stop/ start/ preheating circuit10-134
  • Driver’s cab 10-136
  • Fuses (1)10-136
  • Relais (2)10-136
  • Engine room 10-137
  • Wiring diagrams 10-149
  • Air conditioner (option) 10-159
  • Introduction10-159
  • Function10-160
  • Design of air conditioner10-165
  • Installation of air conditioner 10-166
  • Safety when handling coolants 10-167
  • Operating the air conditioner 10-169
  • Maintenance of the air conditioner10-170
  • Instructions for filling 10-173
  • Exchange of magnetic clutch10-176
  • Exchange of compressor 10-177
  • Troubleshooting10-179

20 TESTING AND ADJUSTING 

  • Standard value table for engine – WA65-320-3
  • Standard value table for chassis – WA65-320-4
  • Standard value table for electrical parts – WA65-320-7
  • Test certificate – WA65-3 20-8
  • Test certificate – WA65-3 Parallel Lift20-9
  • Standard value table for engine – WA75-3/WA85-320-10
  • Standard value table for chassis – WA75-3/WA85-320-11
  • Standard value table for electrical parts – WA75-3/WA85-3 20-14
  • Test certificate – WA75-320-16
  • Test certificate – WA85-320-17
  • Standard value table for engine – WA90-3/WA95-320-18
  • Standard value table for chassis – WA90-3/WA95-320-19
  • Standard value table for electrical parts – WA90-3/WA95-3 20-22
  • Test certificate WA90-3 20-24
  • Test certificate WA95-3 20-25
  • Valve clearance, testing and adjusting20-31
  • Engine compression test 20-32
  • Injection nozzle pressure 20-33
  • Fuel injection timing 20-34
  • Fan belt20-35
  • Engine RPM20-36
  • RPM-dependant drive take-up 20-37
  • Engine stall torque RPM20-38
  • Engine stall torque RPM, test with the hydrostatic drive 20-38
  • Engine stall torque RPM, test with the hydrostatic drive and
  • working hydraulics20-39
  • Feed pump and servo oil pressure20-40
  • Hydraulic pressure cut-off20-41
  • Working hydraulic pressure 20-43
  • Steering oil pressure 20-44
  • Operating time for steering wheel20-45
  • Operating force of steering wheel20-46
  • Brake20-47
  • Brake lining, wear test – WA65-3 20-47
  • Brake disc, wear test – WA75-3/WA85-3/WA90-3/WA95-3 20-47
  • Brake disc clearance – WA75-3/WA85-3 20-48
  • Brake disc clearance – WA90-3/WA95-3 20-49
  • Bleeding the brake system – WA65-3 up to WA95-320-50
  • Inch valve – basic adjustment 20-51
  • Parking brake 20-52
  • Basic adjustment – WA75-3 bis WA95-3 20-52
  • Brake efficiency 20-53
  • Measuring the stopping distance 20-53
  • Parking brake efficiency20-54
  • Travel speed20-55

30 DISASSEMBLY AND ASSEMBLY

  • Comments 30-3
  • Starter assembly 30-4
  • Removal of starter assembly 30-4
  • Installation of starter assembly30-5
  • Alternator assembly 30-6
  • Removal of alternator assembly 30-6
  • Installation of alternator assembly 30-7
  • Water pump assembly 30-8
  • Removal of water pump assembly 30-8
  • Installation of water pump assembly30-10
  • Engine cover assembly 30-11
  • Removal of engine cover assembly 30-11
  • Installation of engine cover assembly 30-12
  • Engine cover support assembly30-13
  • Removal of engine cover support assembly30-13
  • Installation of engine cover support assembly 30-15
  • Engine assembly30-16
  • Removal of engine assembly30-16
  • Installation of engine assembly30-21
  • Clutch assembly 30-24
  • Removal of clutch assembly30-24
  • Installation of clutch assembly 30-25
  • Radiator assembly 30-26
  • Removal of radiator assembly 30-26
  • Installation of radiator assembly30-28
  • Fan and pulley assembly30-29
  • Removal of fan and pulley assembly30-29
  • Installation of fan and pulley assembly30-30
  • Inch brake valve assembly30-31
  • Removal of inch brake valve assembly30-31
  • Installation of inch brake valve assembly 30-32
  • Priority valve assembly 30-33
  • Removal of priority valve assembly 30-33
  • Installation of priority valve assembly30-34
  • Steering valve assembly30-35
  • Removal of steering valve assembly30-35
  • Installation of steering valve assembly 30-37
  • Counterweight assembly30-38
  • Removal of counterweight assembly30-38
  • Installation of counterweight assembly30-39
  • Main control valve assembly30-40
  • Removal of main control valve assembly 30-40
  • Installation of main control valve assembly 30-41
  • Pilot valve assembly 30-42
  • Removal of pilot valve assembly 30-42
  • Installation of pilot valve assembly30-44
  • Monitor assembly30-45
  • Removal of monitor assembly 30-45
  • Installation of monitor assembly30-46
  • Articulated joint assembly30-47
  • Removal of articulated joint assembly 30-47
  • Installation of articulated joint assembly 30-48
  • Variable motor assembly 30-49
  • Removal of variable motor assembly30-49
  • Installation of variable motor assembly30-50
  • Rear axle assembly30-51
  • Removal of rear axle assembly30-51
  • Installation of rear axle assembly30-53
  • Front axle assembly 30-54
  • Removal of front axle assembly30-54
  • Installation of front axle assembly30-56
  • Rear axle (WA65-3/WA75-3/WA85-3)30-57
  • Brake (WA75-3/WA85-3)30-57
  • Wheel hub 30-59
  • Wheel hub onto axle housing 30-60
  • Planetary gear 30-61
  • Bevel pinion support30-62
  • Adjustments of bevel gear set 30-67
  • Taper roller bearings of differential 30-68
  • Disassembly of differential30-70
  • Limited slip differential 30-72
  • Special tools30-73
  • Rear axle (WA90-3/WA95-3) 30-81
  • Checking wear and replacing
  • the braking discs30-81
  • Assembling of braking units 30-84
  • Disassembly of planetary reduction
  • and axle shaft 30-87
  • Assembling of planetary reduction
  • and axle shift30-93
  • Disassembly of bevel pinion30-99
  • Assembly and adjustment of bevel pinion 30-103
  • Special tools 30-112
  • Disassembly of mechanic parking brake unit 30-117
  • Assembly of mechanic parking brake unit 30-120
  • Reduction gear V 30 km/h
  • (WA75-3 through WA95-3) 30-123
  • Disassembly of integrated reduction gear 30-123
  • Assembly of integrated reduction gear 30-134
  • Variable displacement pump assembly 30-147
  • Removal of variable displacement
  • pump assembly30-147
  • Installation of variable displacement
  • pump assembly30-149
  • Hydraulic pump assembly 30-150
  • Removal of hydraulic pump assembly30-150
  • Installation of hydraulic pump assembly30-151
  • Quick-attach coupler assembly 30-152
  • Removal of quick-attach coupler assembly30-152
  • Installation of quick-attach coupler assembly 30-153
  • Steering cylinder assembly 30-154
  • Removal of steering cylinder assembly 30-154
  • Installation of steering cylinder assembly30-155
  • Lift cylinder assembly 30-156
  • Removal of lift cylinder assembly30-156
  • Installation of lift cylinder assembly30-157
  • Dump cylinder assembly 30-158
  • Removal of dump cylinder assembly 30-158
  • Installation of dump cylinder assembly 30-159
  • Replacing of windows in driver’s cab30-160

90 APPENDIX

  • Wiring diagram – Fig 110-151
  • Wiring diagram – Fig 210-152
  • Wiring diagram – Fig 310-155
  • Wiring diagram – Fig 410-156
  • Wiring diagram – Fig 1a10-1583
  • Wiring diagram – Fig 2a10-1584
  • Wiring diagram – Fig 3a10-1587
  • Wiring diagram – Fig 4a10-1588
  • Wiring diagram – Fig 5a 10-15811
 Wiring diagram – Fig. 1a

Wiring diagram – Fig. 1a

♦ Komatsu  WA65-3H-WA95-3H Parallel Lift  WA85-3 WA90-3 WA95-3.pdf (22.5 MB)

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User tags: Komatsu WA65-3 Parallel Lift, Komatsu WA65-3 WHEEL LOADER shop manual, Komatsu WA75-3, Komatsu WA85-3, Komatsu WA90-3 WHEEL LOADER repair, Komatsu WA95-3 WHEEL LOADER repair, Komatsu WHEEL LOADER repair guide manual pdf

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Komatsu WA 70-1 10001 and up Wheel Loader shop service repair manual download

The Komatsu WA70-1 shop service manual has been prepared as an aid to improve the quality of repairs by giving the serviceman 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 is Manual TABLE OF CONTENTS:

ENGINE
1.Testing and adjusting

  • standard value table
  • tool list for testing and adjusting
  • adjusting valve clearance
  • measuring compression pressure
  • testing and adjusting fuel injection timing
  • adjusting fuel injection timing
  • adjusting of fuel cut solenoid
  • measuring operating force and operating angle of accelerator pedal

and more

2.Disassembly and assembly

POWER TRAIN

1.Structure and function

  • Hydraulic circult for power train
  • Torque converter oil outlet valve
  • Transmission control valve
  • Transmission control linkage
  • Drive shaft
  • Axle
  • Differential
  • Final drive
  • Axle mount
  • Tire and wheel

and more

2.Testing and adjusting
3.Disassembly andassembly
4.Maintenance standard
STEERING SYSTEM
1.Structure and function

  • Hydraulic circuit for steering
  • Hydraulic circuit diagram for steering
  • Flow divider valve
  • Steering valve
  • Steering cylinder
  • Center hinge pin

and more

2.Testing and adjusting
3.Disassembly and assembly
4.Maintenance standard
BRAKE SYSTEM

1.Structure and function

  • Brake piping
  • Brake master cylinder
  • Wheel brake
  • Parking brake

and more
2.Testing and adjusting
3.Disassembly and assembly
4.Maintenance syandard

Work equipment

Electrical system

  • Cluster gauge
  • Electric wiring diageram
  • Electric wiring circuit diagram
  • Engine starting circuit
  • Engine shop circuit
  • Preheating circuit

♦ Komatsu  WA70-1.pdf shop manual.pdf(48.7 MB)

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