Komatsu Wheel Loaders Wa150pz 5 Shop Manual

Full download: [Link]

VEBM420100

WA150PZ-5
MACHINE MODEL SERIAL NUMBER

WA150PZ-5 H50051 and up

• This shop manual may contain attachments and optional equipment that are not available in your
area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.

• WA150PZ-5 mounts the SAA4D102E-2 engine.

For details of the engine, see the 102 Series Engine Shop Manual.

© 2005
All Rights Reserved
Printed in Europe 05-05 00-1
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CONTENTS

No. of page
01 GENERAL ................................................................................................................01-1

10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD......................................................................10-1

20 TESTING AND ADJUSTING .......................................................................20-1

30 DISASSEMBLY AND ASSEMBLY ..........................................................30-1

90 OTHERS ....................................................................................................................90-1

00-2 WA150PZ-5
01 GENERAL

GENERAL ASSEMBLY DRAWINGS......................................... 01-2

SPECIFICATIONS ..................................................................... 01-3
WEIGHT TABLE ........................................................................ 01-7
LIST OF LUBRICANT AND COOLANT..................................... 01-9

WA150PZ-5 01-1
GENERAL GENERAL ASSEMBLY DRAWINGS

GENERAL ASSEMBLY DRAWINGS

Item Unit WA150PZ-5

Operating weight (With Teeth) kg 8,480
Rated load kN {kg} 23.5 {2,400}
Bucket capacity (piled) (With Teeth) m3 1.5
Engine model — KOMATSU SAA4D102E-2 Diesel engine
Flywheel horse power kW {HP} / rpm 71 {96} / 2,000
A Overall length (With Teeth) mm 6,600
B Overall height mm 3,035
C Overall height when bucket is raised mm 4,979
D Overall width mm 2,250
E Min. ground clearance mm 400
F Bucket width mm 2,390
G Dumping clearance Tip of bucket/Tip of Teeth mm 2,915/2,775
H Dumping reach Tip of bucket/Tip of Teeth mm 825/960
I Bucket dump angle deg. 45
Tip of bucket/Tip of Teeth mm 5,270 / 5,330
Min. turning radius
Center of outside wheel mm 4,470
F1 km / h 4.6 – 13.0
F2 km / h 13.0
F3 km / h 20.0
F4 km / h 38.0
Travel speed
R1 km / h 4.6 – 13.0
R2 km / h 13.0
R3 km / h 20.0
R4 km / h 38.0

01-2 WA150PZ-5
GENERAL SPECIFICATIONS

SPECIFICATIONS
Machine model WA150PZ-5

Serial No. H50051 and up

Operating weight (With BOC) kg 8,880

Weight

Distribution (front) SAE travel posture kg 3,940

Distribution (rear) SAE travel posture kg 4,940
Bucket capacity (piled) (With BOC) m³ 1.5
Rated load kN {kg} 23.5 {2,400}
Travel speed FORWARD 1st km / h 4.6 – 13.0
FORWARD 2nd km / h 13.0
FORWARD 3rd km / h 20.0
FORWARD 4th km / h 38.0
REVERSE 1st km / h 4.6 – 13.0
Performance

REVERSE 2nd km / h 13.0

REVERSE 3rd km / h 20.0
REVERSE 4th km / h 38.0
Max. rimpull FORWARD kN {kg} 63.7 {6,500}
REVERSE kN {kg} 63.7 {6,500}
Gradeability deg. 25
(Center of outside
Min. turning radius wheel) mm 4,470

Min. turning radius [SAE travel posture]

(Tip of bucket/Tip of BOC) mm 5,165 / 5,185

Overall length (with BOC) mm 6,600

Overall width (chassis) mm 2,250
Bucket width (with BOC) mm 2,390
Overall height (top of cab) mm 3,035
Overall height (Bucket approx. raised to
max.) mm 4,979

Wheel base mm 2,600

Tread mm 1,780
Dimensions

Min. ground clearance mm 400

Max. height of bucket hinge pin mm 3,485
Dumping clearance (Tip of bucket/Tip of
Teeth) mm 2,915 / 2,775

Dumping reach (Tip of bucket/Tip of Teeth) mm 825 / 960

Steering angle deg. 40
Bucket tilt angle (travel posture) deg. 46
Bucket tilt angle (max. height) deg. 66
Bucket dump angle (max. height) deg. 46
Digging depth (10° dump)
(Tip of bucket/Tip of BOC) mm 220 / 255

WA150PZ-5 01-3
GENERAL SPECIFICATIONS

Machine model WA150PZ-5

Serial No. H50051 and up

Model SAA4D102E-2

Type 4-cycle, water-cooled, in-line, 4-cylinder,

direct injection with turbocharger, air-cooled after cooler
No. of cylinders - bore x stroke mm 4 – 102 x 120
Piston displacement l {cc} 3.92 {3,920}
Flywheel horsepower kW / rpm 71 / 2,000
{HP / rpm} {96 / 2,000}
Engine

Maximum torque Nm / rpm 402 / 1,300

{kgm / rpm} {41 / 1,300}
Min. fuel consumption ratio g / kWh {g / HPh} 219 {161}
High idling speed rpm 2,250
Low idling speed rpm 825
Starting motor 24 V 5.5 kW
Alternator 24 V 35 A
Battery (*1) 24 V 92 Ah x 2 pcs.
HST pump Variable displacement swash plate-type piston pump
HST motor 1 Variable displacement swash plate-type piston motor
HST motor 2 Variable displacement swash plate-type piston motor
Power train

Multiple shaft planetary compound-type, spur gear

Transfer constant mesh-type, 2 alternative power systems
Reduction gear Spiral bevel gear, splash lubrication type
Differential Straight bevel gear type, torque portioning
Final drive Planetary gear 1-stage, splash lubrication type
Drive type Front and rear wheel drive
Axle

Front axle Fixed to frame, semi-floating type

Rear axle Center pin support, semi-floating type
Tire size 17.5–R25
Rim size W15L × 24
Tire

Inflation pressure Front tire kPa {kg / cm²} 235 {2.4}

Rear tire kPa {kg / cm²} 235 {2.4}
4 wheel braking, Front and rear wheel independent sys-
Braking system tem control

Main brake Brake type Enclosed wet multiple disc type

Operation method Hydraulically controlled
Brakes

Control method Hydraulic power servo assisted brake

Braking system Speed change gear output shaft braking
Brake type Wet multiple disc type
Parking brake
Operation method Mechanical type
Control method Hand lever type
*1: Battery capacity (Ah) shows the rate of 5 hours.

01-4 WA150PZ-5
GENERAL SPECIFICATIONS

Machine model WA150PZ-5

Serial No. H50051 and up

Type Articulated steering

Steering
control

Control Hydraulic control

Work equipment and Steering pump

• Type Gear type

• Theoretical capacity cm³/rev 63.1

Hydraulic pump

Brake and cooling fan pump

• Type Gear type

• Theoretical capacity cm³/rev 10.5

Transfer lubrication pump
• Type Gear type

• Theoretical capacity cm³/rev 6.4

Type Reciprocating piston type
Steering cylinder

Cylinder inner diameter mm 55

Hydraulic system

Piston rod diameter mm 30

Stroke mm 375
Max. length between pins mm 1,020
Min. length between pins mm 645
Type Reciprocating piston type
Cylinder inner diameter mm 110
Lift cylinder
Cylinder

Piston rod diameter mm 60

Stroke mm 628
Max. length between pins mm 1,659
Min. length between pins mm 1,031
Type Reciprocating piston type
Bucket cylinder

Cylinder inner diameter mm 110

Piston rod diameter mm 55
Stroke mm 628
Max. length between pins mm 1,608
Min. length between pins mm 980

WA150PZ-5 01-5
GENERAL SPECIFICATIONS

Machine model WA150PZ-5

Serial No. H50051 and up

Work equipment control valve

• Type 2-spool type
Control valve
Hydraulic system

• Set pressure MPa {kg / cm²} 20.6 {210}

Steering valve
• Type Orbit-roll type

• Set pressure MPa {kg / cm²} 18.6 {190}

Cooling fan motor
Motor

• Type Fixed displacement piston type

equipment

Link type Single link

Work

Bucket edge type Flat blade with top BOC

01-6 WA150PZ-5
GENERAL WEIGHT TABLE

WEIGHT TABLE

This weight table is a guide for use when transporting or handling components.
Unit: kg

Machine model WA150PZ-5

Serial Numbers H50051 and up

Engine (without coolant and oil) 450

Cooling assembly (without coolant) 71
Cooling fan motor 6
Damper 3

HST pump 56
HST motor 1 26
HST motor 2 26

Transfer 158
Front drive shaft 14
Rear drive shaft 4
Front axle 410
Rear axle 380
Axle pivot (rear axle) 66

Wheel (each) 53
Tire (each) 91
Orbit-roll valve 7
Priority valve 6
Steering cylinder assembly (each) 13
Brake valve 10

Hydraulic tank (without hydraulic oil) 59

3-gear pump unit 20
Work equipment PPC valve 3
Work equipment control valve 19
Lift cylinder assembly (each) 65
Bucket cylinder assembly 56
Engine hood (with side panel) 140
Front frame 590
Rear frame 573

WA150PZ-5 01-7
GENERAL WEIGHT TABLE

Unit: kg

Machine model WA150PZ-5

Serial Numbers H50051 and up

Lift arm (including bushing) 446 - 493

2
Bucket (1.5m , including BOC) 686 - 696
Bell crank 126
Bucket link 20
Counterweight 660
Additional counterweight (1 piece) 100
Fuel tank (without fuel) 70
Battery (each) 33
Operator’s Cab (including air conditioner and interior parts) 755
Operator’s seat 41

01-8 WA150PZ-5
GENERAL LIST OF LUBRICANT AND COOLANT

LIST OF LUBRICANT AND COOLANT

LUBRICANTS, FUELS AND FILLING CAPACITIES

WA150PZ-5 Lubricant and Filling

Short code / Temperature Viscosity
operating Quality grade capacity in
cask lettering range range
medium litres

EO 0030A -30° up to 40° C SAE 0W-30

ACEA E5
EO 0540A -25° up to 40° C SAE 5W-40
or, if not available:
EO 10 -20° up to 10° C SAE 10 14
Engine Engine oil API CD or
EO 30 0° up to 40° C SAE 30 (12.5 **)
API CE or
EO 1030A -20° up to 40° C SAE 10W-30
API CF -4
EO 1540A - 15° up to 50° C SAE 15W-40 *)

ACEA E5
or, if not available: 4.9
Transfer case Engine oil EO 10 -30° up to 40° C SAE 10W*)
API CD or API CE or (4.4 **)
API CF -4

HYD 0530 -30° up to 40° C ISO VG46 *) 104

Hydraulic system Hydraulic oil HVLP, HVLP D
HYD1030 -20° up to 30° ISO VG68 (47**)

AXO 80 80W
Axle oil
AXO Shell: DONAX TD5W30*** SAE 5W-30 *)
Axle with
standard ACEA E5
differential or, if not available:
or Engine oil EO 30 0° up to 40° C SAE 30 front 14
API CD or API CE or
API CF -4

Shell: DONAX TD5W30*** SAE 5W-30 *) rear 14.5

Axle with
Esso: TORQUE FLUID56****
limited-slip Axle oil (*4) AXO
Mobil: MOBILFLUID 424
differential (*3)
Fuchs: TITAN HYDRA ZF20W-40 SAE 20W-40

ASTM D975 No.1 -30° up to -10° C

ASTM D975 No.2 -10° up to 40° C
Fuel tank Diesel fuel CFPP class B 0° up to 40° C 133
DIN-EN 590 CFPP class D -10° up to 40° C -
CFPP class F 20° up to 40° C

Multi purpose
Grease nippels grease on a lith- MPG-A KP2N-20 -30° up to 40° C NLGI-No. 2 –
ium base

Grease box of Multi purpose

central lubrication grease on a lith- MPG-A KP2N-20 -30° up to 40° C NLGI-No. 2 –
unit ium base

Water and
Cooling system SP-C Add antifreeze with corrosion resistor 17
coolant

Air conditioner Coolant NRS R134a (CFC-free) 860 g

*) Work filling
** Top-up quantity
*** North American manufacted DONAX TD 20W-40 must not be used.
**** North American manufacted TORQUE FLUID 56 must not be used.

WA150PZ-5 01-9
GENERAL LIST OF LUBRICANT AND COOLANT

*1: ASTM D975 No. 1

*2: Use only diesel fuel.
*3: For the standard differential, except for "AX080", the oil for machines equipped with the anti-slip differential
in the table below and EO30 can be used. However, in the case of "EO30", depending on conditions such
as the brakes are used and the oil temperature, the brakes may squeal just before the machine stops, but
there is no problem with the brake performance or durability.
*4: The letters "ASD" are stamped on the name plate of machines equipped with the anti-slip differential axle.
*5: For machines equipped with the limited-slip differential axle, select from the oil given in the table below.

Maker Brand Remarks

SHELL DONAX TD 5W-30 North American manufactured DONAX TD

20W–40 must not be used
North American manufactured must not
ESSO TORQUE FLUID 56 be used
MOBIL MOBILFLUID 424
FUCHS RENOGEAR HYDRA ZF 20W–40

01-10 WA150PZ-5
10 STRUCTURE, FUNCTION AND
MAINTENANCE STANDARD

ENGINE MOUNT AND TRANSFER MOUNT 10- 2 3-GEAR PUMP UNIT....................................10-100

DAMPER........................................................ 10- 3 ACCUMULATOR (FOR PPC CIRCUIT) .......10-102
COOLING SYSTEM....................................... 10- 4 LOCK VALVE ...............................................10-103
POWER TRAIN.............................................. 10- 5 E.C.S.S. VALVE ...........................................10-104
POWER TRAIN SYSTEM DIAGRAM ............ 10- 6 ACCUMULATOR (FOR E.C.S.S.) ................10-107
DRIVE SHAFT (PROPELLER SHAFT) ......... 10- 8 HYDRAULIC PIPING OF
HST HYDRAULIC PIPING DIAGRAM ........... 10- 9 COOLING SYSTEM...............................10-108
HST PUMP .................................................... 10-10 COOLING FAN MOTOR...............................10-109
HIGH-PRESSURE RELIEF VALVE ............... 10-12 WORK EQUIPMENT CONTROL VALVE .....10-110
LOW-PRESSURE RELIEF VALVE................ 10-14 WORK EQUIPMENT PPC VALVE ...............10-123
HST CHARGE PUMP .................................... 10-15 WORK EQUIPMENT LINKAGE....................10-130
SPEED-RELATED VALVE (DA VALVE) ....... 10-16 BUCKET .......................................................10-132
HIGH-PRESSURE CUT-OFF VALVE............ 10-17 BUCKET POSITIONER AND
HST MOTOR ................................................. 10-18 BOOM KICK-OUT ..................................10-133
EP SERVO VALVE ........................................ 10-21 WORK EQUIPMENT CYLINDER .................10-139
HA SERVO VALVE ........................................ 10-22 AIR CONDITIONER......................................10-140
FORWARD-REVERSE SHUTTLE VALVE .... 10-23 MACHINE MONITORING SYSTEM .............10-141
TRANSFER.................................................... 10-24 MACHINE MONITOR ...................................10-151
CLUTCH SOLENOID VALVE ........................ 10-35 LIST OF ITEMS DISPLAYED
AXLE .............................................................. 10-36 ON MONITOR........................................10-152
DIFFERENTIAL ............................................. 10-38 ELECTRICAL SYSTEM
LIMITED-SLIP DIFFERENTIAL ..................... 10-44 (HST CONTROLLER SYSTEM) ............10-178
FINAL DRIVE ................................................. 10-48 HST CONTROLLER .....................................10-182
AXLE MOUNTING AND ENGINE START CIRCUIT............................10-183
CENTER HINGE PIN .............................. 10-50 ENGINE STOP CIRCUIT..............................10-185
STEERING PIPING ....................................... 10-55 PREHEATING CIRCUIT...............................10-186
STEERING COLUMN .................................... 10-56 PARKING BRAKE CIRCUIT.........................10-187
PRIORITY VALVE ......................................... 10-57 ELECTRONICALLY CONTROLLED
ORBIT-ROLL VALVE ..................................... 10-60 SUSPENSION SYSTEM........................10-190
STEERING CYLINDER ................................. 10-68 SENSORS ....................................................10-191
EMERGENCY STEERING PIPING ............... 10-70
EMERGENCY STEERING VALVE ................ 10-71
BRAKE PIPING.............................................. 10-74
BRAKE VALVE .............................................. 10-75
INCHING VALVE ........................................... 10-79
CHARGE VALVE ........................................... 10-80
ACCUMULATOR (FOR BRAKE) ................... 10-84
SLACK ADJUSTER ....................................... 10-85
BRAKE ........................................................... 10-88
PARKING BRAKE CONTROL ....................... 10-91
PARKING BRAKE.......................................... 10-92
HYDRAULIC PIPING ..................................... 10-94
WORK EQUIPMENT LEVER LINKAGE ........ 10-96
HYDRAULIC TANK........................................ 10-97

WA150PZ-5 10-1
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE MOUNT AND TRANSFER MOUNT

ENGINE MOUNT AND TRANSFER MOUNT

10-2 WA150PZ-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DAMPER

DAMPER

Unit: mm
No. Check item Criteria Remedy

Distance between HST pump Standard size Repair limit

1 Adjust
mounting face and end of hub 61.2 ± 0.8
2 Wear of flange and insert Repair limit: 1.0 Replace

3. Flange Outline
4. HST pump input shaft • The damper reduces the torsional vibration
5. Hub caused by fluctuation of the engine torque to pro-
6. Cover tect the drive system after the engine from the
7. Flywheel torsional vibration.
8. Insert • The power from the engine is transmitted through
flywheel (7) to flange (3), which absorbs the tor-
sional vibration, and then transmitted through
hub (5) to the HST pump.

WA150PZ-5 10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING SYSTEM

COOLING SYSTEM

1. Oil cooler 4. Reservoir tank

2. After cooler 5. Cooling fan
3. Radiator 6. Cooling fan motor

Specification

Radiator Oil cooler After cooler

Core type AL WAVE–4 CF40–1 AL WAVE

Fin pitch (mm) 3.5 / 2 3.5 / 2 4.0 / 2

Total heat radiating area (m2) 22.0 5.72 5.75

Pressure valve opening pressure 68.6

— —
(kPa {kg/cm2}) {0.7}

Vacuum valve opening pressure 0 – 4.9

— —
(kPa {kg/cm2}) {0 – 0.05}

10-4 WA150PZ-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN

POWER TRAIN

1. Engine
2. Damper
3. HST pump
4. 3-gear pump unit
5. High-pressure hose
6. HST motor 1
7. HST motor 2
8. Transfer
9. Front drive shaft
10. Front axle
11. Rear drive shaft
12. Rear axle

WA150PZ-5 10-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM

POWER TRAIN SYSTEM DIAGRAM

10-6 WA150PZ-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM

1. Engine Outline
2. Damper • The power of engine (1) is transmitted to HST
3. HST pump pump (3) through damper (2) which is installed to
4. Work equipment and Steering pump the flywheel and which absorbs the torsional vi-
5. Brake and cooling fan pump bration of the power,
6. Transfer lubricating oil pump • The power of engine (1) is also transmitted to
7. High-pressure hose HST pump (3), HST charge pump built in HST
8. HST motor 1 pump (3), work equipment and steering pump (4)
9. HST motor 2 connected to HST pump (3), brake and cooling
10. Emergency steering valve (If equipped) fan pump (5), and transfer lubricating oil pump
11. Transfer (6).
12. Transfer clutch • HST pump (3) is equipped with the forward-re-
13. Parking brake verse shifting valve and servo piston, which
14. Front drive shaft changes the discharge direction and discharge
15. Front axle rate of HST pump (3) continuously by changing
16. Differential the swash plate angle.
17. Wet multiple disc brake • HST motors (8) and (9) are installed to transfer
18. Final drive (11) and connected to HST pump (3) by high-
19. Front tire pressure hose (7).
20. Rear drive shaft • The turning direction and speed of HST motors
21. Rear axle (8) and (9) are changed by the hydraulic power of
22. Differential HST pump (3) to control the travel direction and
23. Wet multiple disc brake travel speed of the machine.
24. Final drive • The power of HST motor 1 (8) is transmitted
25. Rear tire through transfer clutch (12) in transfer (11) to the
output shaft.
The power of HST motor 2 (9) is transmitted
through the gear in transfer (11) to the output
shaft.
• Parking brake (13) is installed on the rear side in
transfer (11). It operates the wet multiple disc
brake to stop the machine according to the oper-
ation of the parking brake lever.
• The power for the front side is transmitted
through front drive shaft (14) to front axle (15).
The power for the rear side is transmitted
through rear drive shaft (20) to rear axle (21).
• The power transmitted to axles (15) and (21) is
reduced in speed by the pinion gears of differen-
tials (16) and (22), and then transmitted through
the sun gear shaft to the sun gear.
• The power of the sun gear is reduced in speed by
the planetary mechanisms of final drives (18) and
(24), and then transmitted through the axle shaft
and wheels to tires (19) and (25).

WA150PZ-5 10-7
Komatsu Wheel Loaders Wa150pz 5 Shop Manual
Full download: [Link]
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE SHAFT

DRIVE SHAFT

1. Front axle Outline

2. Front drive shaft • The power from the output shaft of the transfer is
3. Transfer transmitted through front drive shaft (2) and rear
4. Rear drive shaft drive shaft (4) to front axle (1) and rear axle (5).
5. Rear axle • When the machine is articulated or it receives an
impact from the road during travel or a working
impact, the positions of the transfer and front and
rear axles change. The drive shafts can change
their angles and lengths by means of the univer-
sal joints and sliding joints so that the power will
be transmitted without damaging any part even
when the positions of the components change
because of the impacts.

10-8 WA150PZ-5

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