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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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