Komatsu WA75-3 WA85-3 Wheel Loader Service Manual
Komatsu WA65-3, Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 Wheel Loader Shop Manual
This Complete Komatsu Service Repair Workshop Manual PDF Download for the WA65-3, WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 Komatsu Wheel Loader has easy to read text sections with top quality diagrams, pictures, and illustrations. The step-by-step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.
APPLICABLE MODELS :
Komatsu WA65-3 Wheel Loader
Serial Numbers : HA940051 AND UP
Komatsu WA65-3 PARALLEL LIFT Wheel Loader
Serial Numbers : HA050051 AND UP
Komatsu WA75-3 Wheel Loader
Serial Numbers : HA950051 AND UP
Komatsu WA85-3 Wheel Loader
Serial Numbers : A960051 AND UP
Komatsu WA90-3 Wheel Loader
Serial Numbers : HA970051 AND UP
Komatsu WA95-3 Wheel Loader
Serial Numbers : HA980051 AND UP
Table of contents :
SAFETY
GENERAL
STRUCTURE AND FUNCTION
TESTING AND ADJUSTING
DISASSEMBLY AND ASSEMBLY
APPENDIX
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : VEBM950201
Total Pages : 422
This 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 judgments. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-it-yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Expenses !!!!
This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completely searchable PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what you”re looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.
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Komatsu WA75-3 WA85-3 Wheel Loader Service Manual
SAFETY
Safety notice
Preparations for work
Precautions during work
Foreword
How to read the shop manual
Volumes
Distribution and updating
Filing method
Symbols
Hoisting instructions
GENERAL
Dimensions, weights and operating data – WA65-3
Dimensions, weights and operating data – WA65-3 Parallel Lift
Specifications – WA65-3/WA65-3 Parallel Lift
Dimensions, weights and operating data – WA75-3
Specifications – WA75-3
Dimensions, weights and operating data – WA85-3
Specifications – WA85-3
Dimensions, weights and operating data – WA90-3
Specifications – WA90-3
Dimensions, weights and operating data – WA95-3
Specifications – WA95-3
Weight table – WA65-3/WA65-3 Parallel Lift
Deviating weights for WA65-3? Parallel Lift
Weight table – WA75-3/WA85-3
Weight table – WA90-3/95-3
Lubricants and operating mediums – WA65-3
Lubricants and operating mediums – WA75-3/WA85-3
Lubricants and operating mediums – WA90-3/WA95-3
Basic procedures of maintenance
Oil
Fuel
Coolant
Grease
Storing oil and fuel
Filters
Biodegradable hydraulic oils and lubricants
Outline of electric system
Torque list – screws and nuts
STRUCTURE AND FUNCTION
Powertrain
Closed circuit
Hydraulic drive system, 20 km/h – WA65-3 bis WA95-3
Hydraulic drive system, 30 km/h – WA75-3 bis WA95-3 (option)
Variable displacement pump
Regulating valve
Charge pressure limiting valve
Control cylinder
4/3 Way valve with direction control solenoids
Pressure cut-off valve
Safety-/charge valve
Towing
Variable displacement motor
Drive shaft
Axle mounting – front and rear axle
Front axle with drum brake – WA65-3
Front axle – WA75-3/WA85-3
Front axle – WA90-3/WA95-3
Rear axle with distributor box – WA65-3
Rear axle with distributor box – WA75-3/WA85-3
Rear axle with distributor box – WA90-3/WA95-3
Distributor box, single stage (20 km/h) – WA65-3/WA75-3/ WA85-3
Distributor box, single stage (20 km/h) – WA90-3/WA95-3
Distributor box, double stage (30 km/h) – WA75-3/WA 85-3/ WA90-3/WA95-3
Limited slip differential (locking value 25%), front and rear axle – WA65-3/WA75-3/WA85-3
Wheel hub, front and rear axle – WA65-3/WA75-3/WA85-3
Service and parking brake with slack adjuster, front axle – WA65-3/WA75-3/WA85-3
Service and parking brake
Automatic adjuster
Service and parking brake, rear axle – WA75-3/WA85-3
Service and parking brake, rear axle – WA90-3/WA95-3
Service and parking brake circuit – WA65-3
Service and parking brake circuit – WA75-3/WA85-3/ WA90?3/WA95-3
Inch-brake valve
Steering articulation joint
Steering system
Hydraulic circuit diagram of steering system – WA65-3/WA75-3/WA85-3
Hydraulic circuit diagram of steering system – WA90-3/WA95-3
Priority valve
Orbit-roll-valve
Steering relief valve
Work equipment hydraulic
Travel, steering, and work hydraulics – WA65?3
Travel, steering, and work hydraulics – WA65?3
Travel, steering, and work hydraulics – WA65?3 Parallel Lift
Travel, steering, and work hydraulics – WA75?3/WA85-3
Travel, steering, and work hydraulics – WA75?3/WA85-3
Travel, steering, and work hydraulics – WA90?3/WA95-3
Travel, steering, and work hydraulics – WA90?3/WA95-3
PPC-Valve
Operation of PPC-valve
Servo pressure regulating valve
Main control valve
Control circuit for tilt-in/tilt-out (cross-section)
Pressure regulating valve
Shock-anti cavitation valve
Anticavitation valve
Lift cylinder – WA65-3
Lift cylinder – WA75-3/WA85-3
Lift cylinder – WA90-3/WA95-3
Dump cylinder – WA65-3
Dump cylinder – WA65-3 Parallel Lift
Dump cylinder – WA75-3/WA85-3
Dump cylinder – WA90/WA95-3
Steering cylinder – WA65-3/WA75-3/WA85-3
Steering cylinder – WA90-3/WA95-3
Lifting frame with quick-coupler
Quick-coupler
Lifting with quick-coupler – WA65-3? Parallel Lift
Bucket positioner
Function
Operation of proximity switch
Adjusting the bucket positioner
Monitor display
Sensors
Engine oil pressure sensor
Fuel level sensor
Engine coolant temperature sensor
Brake oil reservoir sensor
Ribbon heater temperature sender unit
Ribbon heater
Engine stop/start/preheating circuit
Driver”s cab
Fuses (1)
Relais (2)
Engine room
Wiring diagrams
Wiring diagram – Fig. 1
Wiring diagram – Fig. 2
Wiring diagram – Fig. 3
Wiring diagram – Fig. 4
Air conditioner (option)
Introduction
Function
The coolant circuit
The condenser
The vaporizer
The filter dryer
Design of air conditioner
Installation of air conditioner
Safety when handling coolants
Operating the air conditioner
Maintenance of the air conditioner
Regular maintenance
Instructions for filling
Exchange of magnetic clutch
Exchange of compressor
Troubleshooting
TESTING AND ADJUSTING
Standard value table for engine – WA65-3
Standard value table for chassis – WA65-3
Standard value table for electrical parts – WA65-3
Test certificate – WA65-3
Test certificate – WA65-3 Parallel Lift
Standard value table for engine – WA75-3/WA85-3
Standard value table for chassis – WA75-3/WA85-3
Standard value table for electrical parts – WA75-3/WA85-3
Test certificate – WA75-3
Test certificate – WA85-3
Standard value table for engine – WA90-3/WA95-3
Standard value table for chassis – WA90-3/WA95-3
Standard value table for electrical parts – WA90-3/WA95-3
Test certificate WA90-3
Test certificate WA95-3
Valve clearance, testing and adjusting
Engine compression test
Injection nozzle pressure
Fuel injection timing
Fan belt
Engine RPM
RPM-dependant drive take-up
Engine stall torque RPM
Engine stall torque RPM, test with the ?hydrostatic drive
Engine stall torque RPM, test with the ?hydrostatic drive and working hydraulics
Feed pump and servo oil pressure
Hydraulic pressure cut-off
Working hydraulic pressure
Steering oil pressure
Operating time for steering wheel
Operating force of steering wheel
Brake
Brake lining, wear test – WA65-3
Brake disc, wear test – WA75-3/WA85?3/ WA90-3/WA95-3
Brake disc clearance – WA75-3/WA85-3
Brake disc clearance – WA90-3/WA95-3
Bleeding the brake system – WA65-3 up to WA95-3
Inch valve – basic adjustment
Parking brake
Basic adjustment – WA75-3 through WA95?3
Brake efficiency
Measuring the stopping distance
Parking brake efficiency
Travel speed
DISASSEMBLY AND ASSEMBLY
Comments
Starter assembly
Removal of starter assembly
Installation of starter assembly
Alternator assembly
Removal of alternator assembly
Installation of alternator assembly
Water pump assembly
Removal of water pump assembly
Installation of water pump assembly
Engine cover assembly
Removal of engine cover assembly
Installation of engine cover assembly
Engine cover support assembly
Removal of engine cover support assembly
Installation of engine cover support assembly
Engine assembly
Removal of engine assembly
Installation of engine assembly
Clutch assembly
Removal of clutch assembly
Installation of clutch assembly
Radiator assembly
Removal of radiator assembly
Installation of radiator assembly
Fan and pulley assembly
Removal of fan and pulley assembly
Installation of fan and pulley assembly
Inch brake valve assembly
Removal of inch brake valve assembly
Installation of inch brake valve assembly
Priority valve assembly
Removal of priority valve assembly
Installation of priority valve assembly
Steering valve assembly
Removal of steering valve assembly
Installation of steering valve assembly
Counterweight assembly
Removal of counterweight assembly
Installation of counterweight assembly
Main control valve assembly
Removal of main control valve assembly
Installation of main control valve assembly
Pilot valve assembly
Removal of pilot valve assembly
Installation of pilot valve assembly
Monitor assembly
Removal of monitor assembly
Installation of monitor assembly
Articulated joint assembly
Removal of articulated joint assembly
Installation of articulated joint assembly
Variable motor assembly
Removal of variable motor assembly
Installation of variable motor assembly
Rear axle assembly
Removal of rear axle assembly
Installation of rear axle assembly
Front axle assembly
Removal of front axle assembly
Installation of front axle assembly
Rear axle (WA65-3/WA75-3/WA85-3)
Brake (WA75-3/WA85-3)
Wheel hub
Wheel hub onto axle housing
Planetary gear
Bevel pinion support
Adjustments of bevel gear set
Taper roller bearings of differential
Disassembly of differential
Limited slip differential
Special tools
Rear axle (WA90-3/WA95-3)
Checking wear and replacing the braking discs
Assembling of braking units
Disassembly of planetary reduction and axle shaft
Assembling of planetary reduction and ?axle shift
Disassembly of bevel pinion
assembly and adjustment of bevel pinion
Special tools
Disassembly of mechanic parking brake unit
Assembly of mechanic parking brake unit
Reduction gear V 30 km/h (WA75-3 through WA95-3)
Disassembly of integrated reduction gear
Assembly of integrated reduction gear
Variable displacement pump assembly
Removal of variable displacement pump assembly
Installation of variable displacement pump assembly
Hydraulic pump assembly
Removal of hydraulic pump assembly
Installation of hydraulic pump assembly
Quick-attach coupler assembly
Removal of quick-attach coupler assembly
Installation of quick-attach coupler ?assembly
Steering cylinder assembly
Removal of steering cylinder assembly
Installation of steering cylinder assembly
Lift cylinder assembly
Removal of lift cylinder assembly
Installation of lift cylinder assembly
Dump cylinder assembly
Removal of dump cylinder assembly
Installation of dump cylinder assembly
Replacing of windows in driver’s cab
APPENDIX
Komatsu WA65-3, WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 Wheel Loader Shop Manual