Putting a Komatsu WA65-5, WA70-5 or WA80-5 wheel loader back to factory standard is the job these 306 pages of shop manual VEBM250100 were written for. Wiring diagrams and hydraulic circuit diagrams close out this Komatsu WA65-5, WA70-5, WA80-5 shop manual PDF, so you can trace a dead circuit or a lazy lift arm back to its source. Disassembly and Assembly takes up the largest share, running from the starter, alternator and water pump through the engine, radiator and brake calipers, while Structure and Function explains the variable displacement pump and motor and Testing and Adjusting lays out standard value tables for engine and chassis. Hold charge pressure between 2.4 and 4.5 bar, and refill the cooling system with 9.1 l of 50/50 coolant rated to -34°C. Hydrostatic drive faults hide well on a loader this compact. Bookmarked, text-searchable pages help you pin down the failed component, so you order the right part the first time.
What's Inside This Komatsu WA65-5, WA70-5, WA80-5 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 3-18 | Safety Notice, Preparations for Work, Hoisting Instructions |
| General | 19-36 | Dimensions and Weights, Lubricants and Operating Mediums, Basic Procedures of Maintenance |
| Structure and Function | 37-128 | Powertrain, Variable Displacement Pump, Variable Displacement Motor, Steering System, Air Conditioner |
| Testing and Adjusting | 129-164 | Standard Value Table for Engine, Standard Value Table for Chassis, Test Certificate |
| Disassembly and Assembly | 165-282 | Starter Assembly, Alternator Assembly, Water Pump Assembly, Engine Assembly, Radiator Assembly, Brake Caliper |
| Others | 283-306 | Hydraulic Circuit Diagrams, Wiring Diagrams |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Filling quantity (R134a) | 1200 g | p. 118 |
| Cooling System Proportion of Mixture | 50% Coolant: 50% Water | p. 33 |
| Cooling System Min. Freeze Proofing | -34°C | p. 33 |
| Charge pressure | 2.4-4.5 bar | p. 42 |
| Coolant capacity | 9.1 l | p. 172 |
| New compressor oil fill | 180 cm³ | p. 122 |
| Water pump fastening screws (7) and (8) torque | 19 Nm | p. 174 |
| Engine Oil Capacity (Top-up) | 7.0L | p. 30 |
| Engine Oil Capacity (Total) | 7.5L | p. 30 |
| Cooling System Capacity | 9.1L | p. 30 |
| Cab Fastening Screw Torque | 230 Nm | p. 10 |
| Front Axle Mounting Torque | 800 Nm | p. 53 |
Komatsu WA65-5, WA70-5, WA80-5 Common Problems This Manual Covers
Komatsu WA65-5, WA70-5, WA80-5 engine low on power, compression test reading below standard
Test compression and compare each reading against the 29.5 bar standard on page 131. Any reading at or below the 19.6 bar limit means the engine needs repair before you chase anything else. Next, check injection nozzle pressure and correct it with shims. Then verify fuel injection timing.
Manual Section: Engine Compression Test p. 131Engine coolant temperature warning triggers at 105°C during long loading shifts in warm weather
Check fan belt deflection first and adjust it to 10 mm per page 131. Verify the coolant mix is 50% coolant to 50% water as listed on page 33, and fill the system to its 9.1 L capacity on page 31. Inspect the radiator assembly and compare sensor readings against the 106°C abnormal threshold on page 93.
Manual Section: Structure and Function p. 92Hydrostatic drive weak, with charge pressure out of specification on the variable displacement pump
Measure charge pressure and compare it against 2.4 to 4.5 bar on page 42. If it reads low, test engine stall torque RPM with the hydrostatic drive and working hydraulics loaded. Then check RPM-dependent drive take-up pressure before you pull the variable displacement pump or motor.
Manual Section: Structure and Function p. 42Loader working hydraulics weak, with main pressure release valve or hydraulic pressure cut-off out of adjustment
Test working hydraulic pressure and adjust the main pressure release valve following the Working Hydraulic Pressure procedure in Testing and Adjusting. Then test and adjust the hydraulic pressure cut-off setting. If pressure still won't come up, trace the circuit on the hydraulic schematic on page 287.
Manual Section: Working Hydraulic PressureAir conditioner weak cooling output with low pressure fault and compressor switching on and off
Check the system for leaks before adding refrigerant. Once it's sealed, recharge with 1200 g of R134a as listed on page 118. If you replace the compressor, fill the new unit with 180 cm³ of oil per page 122. Then verify compressor switching and cooling output against the Air Conditioner Troubleshooting chart.
Manual Section: Air Conditioner TroubleshootingParking brake fails to hold the loader during parking brake efficiency test
Test parking brake efficiency and adjust the parking brake following the Parking Brake Efficiency procedure on page 163. Then measure stopping distance to check service brake efficiency. If adjustment won't bring it back, remove and inspect the brake caliper using the Disassembly and Assembly section before the machine works on a grade again.
Manual Section: Parking Brake Efficiency p. 163Frequently Asked Questions
What are the air filter replacement specifications for the Komatsu WA65-5, WA70-5, WA80-5 wheel loader?
Filters are critical safety components that must be replaced periodically as specified in the Operation and Maintenance Manual. When operating under severe conditions, you must replace filters at shorter intervals based on the oil and fuel (sulfur content) being used. Never attempt to clean and reuse cartridge-type filters. p. 34
How does fuel sulphur content change the engine oil change interval on the Komatsu WA65-5, WA70-5, WA80-5?
The manual does not give a fuel filter interval; it ties fuel quality to engine oil service instead. If fuels with a sulphur content between 0.5 and 1.0% are used, the engine oil change intervals must be cut in half; above 1.0% sulphur, they must be quartered. p. 30
What is the tightening torque for the cab fastening screws on a Komatsu WA65-5, WA70-5, WA80-5?
When tipping the driver's cab, the fastening screws (2 on the left and 2 on the right) must be tightened to a torque of 230 Nm. p. 10
What is the cold engine valve clearance on the Komatsu WA65-5, WA70-5, WA80-5 wheel loader?
For the 4D95LE-3 engine, the valve clearance when the engine is cold is 0.35 mm for the intake valves and 0.50 mm for the exhaust valves. p. 142
What is the standard engine oil capacity for the WA65-5 and WA70-5?
The standard engine oil capacity for the WA65-5 and WA70-5 is 7.5 liters, with a top-up quantity of 7.0 liters. p. 30
Do I get instant access to this Komatsu WA65-5 Shop Manual?
Straight to your device: 306 pages of searchable Shop Manual, downloadable the moment payment goes through.
Am I free to print this Komatsu WA65-5 Shop Manual?
Yes. It prints from any PDF reader, so run off the pages you need for your own repair work.
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