Komatsu WA65-3, WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 Wheel Loader Shop Manual

This Complete 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
HSerial 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 judgements. 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 Costs !!!!

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 completly searcheble 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 your 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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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
- - Automatical adjuster
- Service and parking brake, rear axle – WA75-3/WA85-3
- Service and parking brake, rear axle – WA90-3/WA95-3
- Sevice and parking brake circuit – WA65-3
- Sevice 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-anticavitation 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

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