Komatsu WA65-3, WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 Wheel Loader Workshop Repair Manual PDF - MKMTSWA65WA95.zip
A full workshop service and repair manual, complete with electrical wiring diagrams, covering the Komatsu Wheel Loader models WA65-3, WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, and WA95-3. It contains every technical detail needed to service, troubleshoot, fix, and overhaul these machines the way trained technicians do.
Inside, the Komatsu Wheel Loader WA65-3, WA65-3 Parallel Lift, WA75-3, WA85-3, WA90-3, WA95-3 shop manual provides:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
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VEAM940600 - Wheel Loader WA65-3 Operation & Maintenance Manual.pdf
VEAM950200 - Wheel Loader WA75-3 Operation & Maintenance Manual.pdf
VEAM950400 - Wheel Loader WA75-3 Operation & Maintenance Manual.pdf
VEAM950600 - Wheel Loader WA75-3, WA85-3 Operation & Maintenance Manual.pdf
VEAM960200 - Wheel Loader WA85-3 Operation & Maintenance Manual.pdf
VEAM960400 - Wheel Loader WA85-3 Operation & Maintenance Manual.pdf
VEAM960600 - Wheel Loader WA85-3 Operation & Maintenance Manual.pdf
VEAM980200 - Wheel Loader WA95-3 Operation & Maintenance Manual.pdf
VEAM980400 - Wheel Loader WA95-3 Operation & Maintenance Manual.pdf
VEAM980500 - Wheel Loader WA95-3 Operation & Maintenance Manual.pdf
VEAM980600 - Wheel Loader WA95-3 Operation & Maintenance Manual.pdf
VEAM980800 - Wheel Loader WA95-3 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,611 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
VEAM250200 - Wheel Loader WA65-5 Operation & Maintenance Manual....3
Cover....3
1. Introduction....4
1.1. Product publications information....5
1.2. Foreword....7
EU Directives....8
1.3. Safety information....10
1.4. Introduction....12
1.4.1. Intended use....12
1.4.2. Breaking-in the machine....13
1.5. Location of plates....14
1.5.1. Machine identification plate (PIN)....14
1.5.2. Engine name-plate....14
1.5.3. Axle serial no. plate....15
1.5.4. Transmission serial no. plate....15
1.5.5. ROPS/FOPS-Cab serial no. plate....15
1.5.6. Seat operator serial no. plate....16
1.5.7. Table to enter serial no. and distributor....16
1.6. Emission control warranty....17
1.6.1. Emission control warranty statement (Applies to Canada only)....17
1.7. Garantie sur le contrôle des émissions....18
1.7.1. Énoncé de garantie sur le contrôle des émissions ( applicable au Canada seulement)....18
1.8. Table of contents....19
1.9. Dimensions, weights and operating data....26
1.10. CE-conforming equipment....27
1.10.1. CE-conforming equipment – part 1....27
1.10.2. CE-conforming equipment – part 2....27
1.10.3. Manufacturer-supplied CE-conforming equipment, according to document 42T 93 21080....28
1.11. Loading and securing....31
Table of contents....19
2. Safety....34
2.1. General safety measures....35
2.1.1. Safety instructions....35
2.1.2. Safety devices....35
2.1.3. Emergency exit....35
2.1.4. Clothing and personal protection....36
2.1.5. Machine modifications....36
2.1.6. Before you leave the driver’s seat....36
2.1.7. Mounting and dismounting....37
2.1.8. Fire prevention and fire fighting....37
2.1.9. Protection against asbestos dust....38
2.1.10. Protection against injuries....38
2.1.11. Working at high temperatures....39
2.1.12. Roll-over protection system (ROPS)....39
2.1.13. Attachment for protection against falling objects (FOPS)....39
2.1.14. Attachments....40
2.1.15. Battery....40
2.2. Safety precautions during operation....41
2.2.1. Prior to daily starting up....41
Workplace safety....41
In the driver's cab....41
Indoor operation....42
Gas, dust, and inflammable vapours....42
Mirrors, windows and lighting....42
2.2.2. Machine operation....43
Before you start the engine....43
Reversing....43
Driving....44
Driving on slopes....44
Emergency Lowering System....45
Working close to power lines....46
Loading....47
Good Vision....47
Working on snow....47
Height limitation....48
Brakes....48
Working on loose soil....48
Working with the forklift truck attachment....48
Parking the machine....50
2.2.3. Transport....51
Loading and unloading the machine....51
Transport....51
2.3. Precautions for maintenance....52
2.3.1. Personnel....52
2.3.2. Before carrying out maintenance ....52
2.3.3. During maintenance....59
2.3.4. Tires....63
2.4. Safety labels on the machine....65
2.4.1. Positions and order numbers of information labels....65
2.4.2. Positions and order numbers of safety labels....66
3. Operation....68
3.1. General view....69
3.1.1. General view of the machine....69
3.1.2. Controls and indicators....70
Overall view....70
Switches, controls and warning lights....71
3.2. Description of the individual elements....72
3.2.1. Instrument panel....72
Warning lights....73
Control lamps....75
Measuring indicators....79
3.2.2. Switches....81
3.2.3. Control levers and pedals....88
3.2.4. Articulated steering catch....93
3.2.5. Traction device....93
3.2.6. Socket (12 V)....94
3.2.7. Door unlocking system....94
3.2.8. Alarm horn for reverse driving – option....94
3.2.9. Fuses....95
3.2.10. Slow-blowing fuses....96
3.2.11. Adjusting the heater and ventilation system....97
3.2.12. Air-conditioning....98
3.3. Operation....99
3.3.1. Pre-start checks....99
Visual inspection....99
Pre-start checks....101
Adjustments prior to machine start....106
Adjusting the driver’s seat....106
3.3.2. Starting the engine....110
Warming up the engine....111
3.3.3. Driving with the machine....112
Start-up....112
3.3.4. Changing the driving direction....114
3.3.5. Turning and steering....115
3.3.6. Braking....116
3.3.7. Stopping the machine....118
3.3.8. Operating the work equipment....119
Multifunctional lever....119
Control lever for special equipment....120
Switching lever of bucket....121
3.3.9. Working with the wheeled loader....122
Tire-appropriate operation....122
Switching on the 100 % differential lock (if equipped)....122
Loading work....123
Removal work....123
Excavation work....125
Planing....126
Transporting....127
Unloading....127
Working with the forklift truck attachment....128
3.3.10. Precautions for special operations....130
Permissible water depth....130
Working on snow....130
Dumping on steep slopes....130
Working in the vicinity of electrical overhead lines....130
Operation on slopes....130
Working on loose soil....130
If the service brake breaks down....130
Precautionary measures when driving up or down....131
Precautionary measures during machine travel....132
3.3.11. Adjusting the position of the work equipment....133
Selecting a work unit....133
Removing the work unit....135
Picking up the multi-purpose bucket....136
Removing the multi-purpose bucket....138
Level indicator for the bucket....138
3.3.12. Parking the machine....139
3.3.13. Switching off the engine....140
3.3.14. Check after stopping the engine....140
3.3.15. Locking....140
3.3.16. Tire handling....141
Precautionary measures when handling tires....141
Tire pressure....141
3.4. Transporting the machine....143
3.4.1. Securing the articulated steering....143
3.4.2. Lifting the machine....144
3.4.3. Driving the machine onto loading area of transport vehicle....145
3.4.4. Securing the machine during the transport....146
3.4.5. After transport....146
3.5. Cold weather operation....147
3.5.1. Before the cold season....147
3.5.2. Precautions after completion of work....148
3.5.3. After the cold season....148
3.6. Long-term storage....149
3.6.1. Before storage....149
3.6.2. During storage....149
3.6.3. After storage....150
4. Troubleshooting....152
4.1. Towing the machine....153
4.2. Starting the engine with a booster cable....157
4.3. For insufficient braking effect....159
4.3.1. Checking the service brake....159
4.3.2. Checking the parking brake function....159
4.4. Emergency steering properties....160
4.5. Emergency lowering....160
4.6. Other troubles....161
4.6.1. Electrical system....161
4.6.2. Engine....162
4.6.3. Hydraulic system....165
4.6.4. Brakes....167
4.6.5. Steering....167
4.6.6. Axles....168
4.6.7. Driver's cab....168
5. Maintenance....170
5.1. Maintenance guide....171
5.2. Maintenance basics....178
5.2.1. Oil, fuel and coolant specifications....178
Oil....178
Fuel....179
Coolant....180
Grease....180
Storing oil and fuel....181
Filters....181
Biodegradable hydraulic oil and lubricants....181
5.2.2. Specifications of the electrical system....182
5.2.3. Wearing parts list....183
5.3. Lubricants, fuels and filling capacities....184
5.3.1. Lubrication chart....185
5.4. Tools and standard tightening torques (bolts, nuts)....186
5.4.1. Introduction of recommended tools....186
5.4.2. Torque list....187
5.5. Periodical replacement of safety-critical parts....189
5.6. Maintenance schedule chart....190
5.7. Service procedure....192
5.7.1. Pre-start checklist....192
Cooling system – checking the coolant level, topping up coolant....192
Cleaning the radiator segments....193
V-Belt, checking the condition....193
Engine, checking the oil level, topping up oil....193
Checking the fuel level – refuelling....195
Water separator at the fuel filter – Draining water and dirt sediments....196
Hand pump - Checking the oil level....196
Checking the controls....197
Checking the electrical connections....197
Heater/air conditioning – checking rate of air flow....198
Miscellaneous tests before starting work....198
5.7.2. Maintenance upon demand....199
Checking the air-conditioning system....199
Checking the window washing-fluid level, adding fluid....200
Re-charging a built-in battery....201
5.7.3. Maintenance after the first 50 operating hours....202
Hydraulic system, replacing the filter insert....202
Checking and tightening the wheel nuts....203
5.7.4. Maintenance after the first 250 operating hours....204
Front and rear axle – oil change....204
Transfer box gearing – changing oil....205
Checking and adjusting the valve play....205
5.7.5. Maintenance every 10 operating hours....206
Lubrication, articulated steering....206
5.7.6. Maintenance every 50 operating hours....207
Checking the service brake and oil level, refilling oil....207
Battery – checking the acid level....208
Lubrication....209
5.7.7. Maintenance every 250 operating hours....210
V-Belt, generator – checking and adjusting the tension....210
Air filter, removing and re-installing the filter insert, checking and cleaning the filter insert....211
Lubrication, steering cylinder....214
Lubrication, self-aligning bearings of rear axle....215
5.7.8. Maintenance every 500 operating hours....216
Engine – changing oil and replacing the oil filter cartridge....216
Replacing the oil filter cartridge....217
Changing the fuel filter and filter element....218
Purging the fuel system....219
Purging the low pressure side....219
Purging the high pressure side....219
Air filter, replacing the filter insert, replacing the safety filter....220
Heater/air conditioning – cleaning/replacing filter fleece or cleaning condenser....221
E.C.S.S.-pressure accumulator (Option) - checking gas pressure....222
Front and rear axle – checking the oil level....223
Transfer box gearing – checking and changing oil....224
5.7.9. Maintenance every 1000 operating hours....225
V-Belt, generator – checking and adjusting the tension....225
Service Brake - Checking and adjusting oil....225
Checking and adjusting system pressures....225
Have the system pressures checked and adjusted at an authorized Komatsu garage...225
Hydraulics – Exchanging the venting filters....226
Hydraulic system, replacing the filter insert....227
5.7.10. Maintenance every 1500 operating hours....228
Front and rear axle – oil change....228
Transfer box gearing – checking and changing oil....229
5.7.11. Maintenance every 2000 operating hours....230
Cooling system – exchanging coolant and cleaning the system....230
Checking and adjusting the valve play....232
Hydraulic system, oil change....233
Ventilating the hydraulic oil tank....234
Checking the fuel pump....235
Checking the fuel and coolant tubes, replacing the tubes (if required)....235
Checking the water pump....235
5.7.12. Maintenance every 4000 operating hours....236