2. 00-2 WD900-3
GENERAL
(1)
CONTENTS
No. of page
01 GENERAL............................................................................................................................ 01-1
10 STRUCTURE AND FUNCTION................................................................ 10-1
20 TESTING AND ADJUSTING........................................................................ 20-1
30 DISASSEMBLY AND ASSEMBLY....................................................... 30-1
40 MAINTENANCE STANDARD ..................................................................... 40-1
90 OTHERS................................................................................................................................ 90-1
3. WD900-3 01-1
GENERAL ASSEMBLY DRAWING ..............................................................................................................01- 2
SPECIFICATIONS ........................................................................................................................................01- 3
WEIGHT TABLE............................................................................................................................................01- 6
LIST OF LUBRICANT AND WATER.............................................................................................................01- 8
01 GENERAL
5. WD900-3 01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model WD900-3
Serial No. 50001 and up
Weight
Operating weight kg 100,000
Distribution (front) kg 50,000
Distribution (rear) kg 50,000
Performance
Blade capacity m3
26.0
Travel speed
FORWARD 1st km/h 7.0
FORWARD 2nd km/h 12.3
FORWARD 3rd km/h 28.0
REVERSE 1st km/h 7.1
REVERSE 2nd km/h 12.4
REVERSE 3rd km/h 28.3
Max. rimpull kN {kg} 686.5 {70,000}
Gradeability deg 25
Min. turning
radius
Center of outside wheel mm 9,200
Outside portion of blade mm 11,285
Dimensions
Overall length mm 12,035
Overall width without blade mm 4,585
Blade width mm 6,470
Blade height mm 2,160
Overall height (top of ROPS cab) mm 5,215
Wheelbase mm 5,450
Tread mm 3,350
Min. ground clearance mm 480
6. 01-4 WD900-3
GENERAL SPECIFICATIONS
Machine model WD900-3
Serial No. 50001 and up
Engine
Model SA12V140-1
Type
4-cycle, water-cooled, V type,
12-cylinder direct injection,
with 2-turbocharger, after-cooler
No. of cylinders - bore x stroke mm 12 – 140 x 165
Piston displacement l {cc} 30.48 {30,480}
Performance
Flywheel horsepower kW/rpm {HP/rpm} 637/2,000 {853/2,000}
Maximum torque Nm/rpm {kgm/rpm} 4,090/1,300 {417/1,300}
Fuel consumption ratio g/kWh {g/HPh} 200 {145}
High idling speed rpm 2,220
Low idling speed rpm 650/850
Starting motor 24 V, 7.5 kW x 2
Alternator 24 V, 75 A
Battery 12 V, 200 Ah x 4
Powertrain
Torque converter
3-element, 1-stage, single-phase
(TCA51-1A)
Transmission
Planetary gear, multiple-disc,
hydraulically actuated, modulation type
Reduction gear Spiral bevel gear
Differential Straight bevel gear
Final drive Planetary gear, single reduction, oil bath
Axle,wheel
Drive type Front/rear-wheel drive
Front axle Fixed-frame, full-floating
Rear axle Center pin support type, full-floating
Tire 45/65 R45 XLDD1 (L-4)
Wheel rim 36.00 x 45WTB
Inflation pressure kPa {kg/cm2
} 667 {6.80}
Brakes
Main brake
Front/rear wheel braking,
separate front/rear wheel, wet disc,
hydraulically actuated
Parking brake
Mounted on front axle input shaft, dry disc,
hydraulically release spring apply
7. WD900-3 01-5
GENERAL SPECIFICATIONS
Machine model WD900-3
Serial No. 50001 and up
Steering
system
Type Articulated type
Structure Fully hydraulically power steering
Hydraulicsystem
Hydraulicpump
delivery
Torque converter, transmission pump l/min
421
(Gear type: SAR(4)112+SAR(3)100)
Steering pump l/min
307
(Fixed capacity piston pump: HPF76+71)
Switch pump l/min
405
(Fixed capacity piston pump: HPV95+95)
Additional oil cooler
fan pump
l/min
51
(Gear type: SAR(1)025)
Front brake cooling pump l/min
67.8
(Gear type: SBL(1)24)
Rear brake cooling pump l/min
67.8
(Gear type: SBR(1)24)
PPC pump l/min
68
(Gear type: SAR(1)032)
Brake pump l/min
29
(Gear type: SAR(1)014)
Work equipment pump l/min
405
(Variable capacity piston pump: HPV90+90)
Controlvalve
Setpressure
Transmission valve MPa {kg/cm2
}
2.5 {25}
(Spool type, electric control)
Steering demand valve MPa {kg/cm2
}
31.4 {320}
(Fully hydraulic type)
PPC valve MPa {kg/cm2
}
3.7 {38}
(2-lever type)
Main control valve MPa {kg/cm2
}
31.4 {320}
(2-spool type)
Cylinder
Steering cylinder No. - bore x stroke mm
Reciprocating piston
1 – 160 x 503
Lift cylinder No. - bore x stroke mm
Reciprocating piston
1 – 200 x 1,300
Tilt cylinder No. - bore x stroke mm
Reciprocating piston
2 – 225 x 240
Work
equipment
Blade type Semi U-blade
Blade frame type Outer frame
8. 01-6 WD900-3
GENERAL WEIGHT TABLE
WEIGHT TABLE
k This weight table is a guide for use when transporting or handling components.
Unit: kg
Machine model WD900-3
Serial No. 50001 and up
Engine 3,200
Radiator 1,200
Torque converter 590
Transmission 2,300
Damper 178
Upper drive shaft 68.5
Center drive shaft 190
Front drive shaft 180
Rear drive shaft 190
Center support 154
Front axle 8,190
Rear axle 7,700
Front differential assembly 1,226
Rear differential assembly 1,256
Planetary carrier assembly (each) 238
Planetary hub assembly (each) 600
Axle pivot (Rear axle) 286
Wheel (each) 845
Tire (each) 2,130
Steering demand valve 58
Steering cylinder (each) 203
Hydraulic tank 823
Work equipment pump 167
Parking brake assembly 185
Torque converter charging + PPC + brake pump 49
Switch pump 141
Switch + additional oil cooler fan pump 151
Steering pump 141
Fender and guard assembly 1,393
PPC valve 5.5
Main control valve (each) 95
DC · CO valve 90
Lift cylinder (each) 621
Tilt cylinder 598
Fender and ladder assembly 1,720
9. WD900-3 01-7
GENERAL WEIGHT TABLE
Unit: kg
Machine model WD900-3
Serial No. 50001 and up
Engine hood
88 (Top)
28 (Side)
Front frame 9,966
Rear frame 9,855
Outer frame (L.H.) 1,136
Outer frame (R.H.) 1,148
H linkage 1,408
Y linkage 1,338
Support (L.H.) 1,909
Support (R.H.) 1,913
Blade 7,149
Counterweight 2,900
Fuel tank 780
Battery (each) 59
Cab 430
Air conditioner unit 55
Operator’s seat 48
Floor plate 348
ROPS support assembly 1,387
10. 01-8 WD900-3
GENERAL LIST OF LUBRICANT AND WATER
LIST OF LUBRICANT AND WATER
Note 1:
For axle oil, use only recommended oil as follows.
SHELL : DONAX TD
MOBILE : MOBILFLUID 424
ESSO : TORQUE FLUID 56
It is possible to substitute engine oil CLASS-CD SAE30 for axle oil.
If noise comes from the brake, it is no problem of durability.
a In cold areas when the hydraulic oil temperature is low, if the steering wheel is turned and the machine is
stopped in that position, there may be a time lag before the machine turns and stops.
If this happens, turn the steering wheel slowly to the left and right (repeat for about 10 minutes) and the oil
inside the steering valve will be warmed up.
*1: [When working in particularly severe conditions, use a multi-purpose grease containing 3 – 5% molybde-
num.
*2: For machines equipped with an auto-grease system, if the machine is operated in temperatures below
–20°C, use lithium-based grease No. 0 for the grease.
11. WD900-3 01-9
GENERAL LIST OF LUBRICANT AND WATER
REMARK
• When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic mainte-
nance hours described in this manual.
• Change oil according to the following table if fuel
sulphur content is above 0.5%.
• When starting the engine in an atmospheric
temperature of lower than 0°C, be sure to use
engine oil of SAE10W, SAE10W-30 and
SAE15W-40, even though an atmospheric tem-
perature goes up to 10°C more or less in the day
time.
• Use API classification CD as engine oil and if
API classification CC, reduce the engine oil
change interval to half.
• There is no problem if single grade oil is mixed
with multigrade oil (SAE10W-30, 15W-40), but
be sure to add single grade oil that matches the
temperature in the table.
• We recommend Komatsu genuine oil which has
been specifically formulated and approved for
use in engine and hydraulic work equipment
applications.
• Specified capacity: Total amount of oil including
oil for components and oil in piping.
• Refill capacity: Amount of oil needed to refill sys-
tem during normal inspection and maintenance.
ASTM: American Society of Testing and Material
SAE : Society of Automotive Engineers
API : American Petroleum Institute
Fuel sulphur content
Change interval of oil in
engine oil pan
0.5 to 1.0 % 1/2 of regular interval
Above 1.0 % 1/4 of regular interval
12. WD900-3 30-21
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
(1)
REMOVAL AND INSTALLATION
OF STARTING MOTOR
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Remove side cover (1).
2. Remove fuel control lever (2) together with
bracket (3).
3. Disconnect connectors (4) (ER1, 2, 3).
4. Disconnect connectors (5) (ER06, 07).
5. Disconnect cables (6) and (7).
6. Remove starting motors (8) and (9).
INSTALLATION
• Carry out installation in the reverse order to
removal.
13. 30-22 WD900-3
DISASSEMBLY AND ASSEMBLY ALTERNATOR
(1)
REMOVAL AND INSTALLATION
OF ALTERNATOR
REMOVAL
k Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Open side cover (1).
2. Disconnect connectors (2) (E20, 21, 22). [*1]
3. Loosen locknuts (3).
4. Remove lock bolt (4).
5. Remove lock bolt (5) and turn down adjustment
bolt (6) toward the air conditioner compressor.
[*2]
6. Loosen the alternator mounting bolt, then
remove drive belt (7). [*3]
7. Remove the mounting bolt, then remove alterna-
tor (8).
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
3 Terminal mounting nut:
Terminal R: 1.9 – 2.5 Nm {0.19 – 0.25 kgm}
Terminal E: 3.2 – 4.4 Nm {0.33 – 0.45 kgm}
Terminal B: 16.1 – 22.1 Nm {1.65 – 2.25 kgm}
[*2]
3 Lock bolt:
54 – 123 Nm {5.5 – 12.5 kgm}
[*3]
a Adjust the deflection of the belt to the speci-
fied dimension. For details, see TESTING
AND ADJUSTING, Testing and adjusting al-
ternator belt tension.
14. WD900-3 30-23
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
(1)
REMOVAL AND INSTALLATION
OF ENGINE OIL COOLER
REMOVAL
1. Open the left cover.
2. Loosen radiator drain valve and drain cooling
water.
a If the coolant contains antifreeze, dispose of
it correctly.
3. Remove fuel injection pump (1) assembly for
right bank. [*1]
a For details, see REMOVAL AND INSTALLA-
TION OF FUEL INJECTION PUMP FOR
RIGHT BANK (WITHOUT GOVERNOR).
4. Remove front oil cooler assembly (2).
5. Remove rear oil cooler assembly (3).
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
a Install fuel injection pump for right bank ac-
cording to REMOVAL AND INSTALLATION
OF FUEL INJECTION PUMP FOR RIGHT
BANK.
a Tighten drain valve and add water to the
specified level, and then run the engine to
circulate the water then check the water level
of reservoir tank.
15. 30-24 WD900-3
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP FOR LEFT BANK
(1)
REMOVAL AND INSTALLATION
OF FUEL INJECTION PUMP
FOR LEFT BANK
(WITH GOVERNOR)
REMOVAL
k Close valve between fuel tank and fuel filter.
1. Open left side cover.
2. Remove cover (1).
3. Remove control rods (2).
4. Disconnect injection pump lubrication tubes (3).
5. Disconnect fuel hoses (4).
6. Disconnect air tube (5).
7. Disconnect fuel injection tubes (6). [*1]
8. Remove mounting bolts at injection pump end to
remove rack control rod (7).
9. Remove coupling lock bolt (9).
10. Remove mounting bolts, then remove fuel injec-
tion pump.
a When removing fuel injection pump, be care-
ful not to drop the key.
4 Fuel injection pump: 30 kg
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
3 Sleeve nut: 24 ± 1 Nm {4 ± 0.1 kgm}
a Check fuel injection timing according to
TESTING AND ADJUSTING FUEL INJEC-
TION TIMING.
DEW3906
16. WD900-3 30-25
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP FOR RIGHT BANK
(1)
REMOVAL AND INSTALLATION
OF FUEL INJECTION PUMP
FOR RIGHT BANK
(WITHOUT GOVERNOR)
REMOVAL
k Close valve between fuel tank and fuel filter.
1. 1.Open left side cover.
2. Remove lower cover (1) of coupling part.
3. Disconnect injection pump lubrication tubes (2).
4. Disconnect fuel hoses (3).
5. Disconnect fuel injection tubes (4). [*1]
6. Remove mounting bolts at injection pump end to
remove rack control rod (5).
7. Remove coupling lock bolts (6).
8. Remove mounting bolts, then remove fuel injec-
tion pump.
a When removing the fuel injection pump, be
careful not to drop key.
4 Fuel injection pump: 23 kg
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
3 Sleeve nut: 24 ± 1 Nm {2.4 ± 0.1 kgm}
a Check fuel injection timing according to
TESTING AND ADJUSTING FUEL INJEC-
TION TIMING.
17. 30-26 WD900-3
DISASSEMBLY AND ASSEMBLY WATER PUMP
(1)
REMOVAL AND INSTALLATION
OF WATER PUMP
REMOVAL
1. Open left side cover.
2. Loosen drain valve and drain cooling water.
a If cooling water contains antifreeze, dispose
of it correctly.
3. Remove cover (1).
4. Remove corrosion resistor (2).
5. Disconnect hoses (3).
6. Disconnect bypass pipe (4).
7. Remove water pump (5).
4 Water pump: 22 kg
INSTALLATION
• Carry out installation in the reverse order to
removal.
a Tighten drain valve and add water to speci-
fied level, and then run the engine to circu-
late water, then check water level of
reservoir tank.
18. WD900-3 30-27
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
(1)
REMOVAL AND INSTALLATION
OF NOZZLE HOLDER
REMOVAL
k Stop the machine on level ground and lower the
work equipment completely to the ground, then
put blocks under the wheels to prevent the ma-
chine from moving.
1. Remove the engine hood.
2. emove head cover mounting bolt (1), then
remove head cover (2). [*1]
3. Remove lock nut (4), then pull out connection
(5). [*2]
4. Remove bolt (6), then remove holder (7). [*3]
5. Fully screw forcing screw [1] (10 mm, P = 1.5) in
the nozzle holder, then pull out nozzle holder (8)
by levering it up with a bar.
a When pulling out the nozzle holder, clean
around it so that foreign matter will not enter
the empty hole.
a Check that the gasket is fitted to the nozzle
end.
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
3 Head cover mounting bolt:
3.9 ± 0.1 Nm {0.4 ± 0.1 kgm}
[*2]
3 Connection: 37 ± 3 Nm {3.8 ± 0.3 kgm}
3 Lock nut: 39 ± 5 Nm {4.0 ± 0.5 kgm}
[*3]
3 Bolt: 66.2 ± 7.4 Nm {6.75 ± 0.75 kgm}
19. 30-28 WD900-3
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
(1)
REMOVAL AND INSTALLATION
OF TURBOCHARGER
REMOVAL
k Stop the machine on level ground and lower the
work equipment completely to the ground.
k Disconnect the cable from the negative (–) ter-
minal of the battery.
1. Remove mufflers (1).
2. Remove handrail (2).
3. Sling and remove engine hood (3).
4. Disconnect air cleaner connecting hose.
5. Disconnect Komaclone tubes (5).
6. Remove mufflers (6).
7. Disconnect connectors (7).
8. Remove bolts (8), then remove exhaust elbows (9).
a Check the number of the shims.
9. Remove elbows (10).
a Check the number of the shims.
10. Disconnect lubrication oil inlet hoses (11).
11. Disconnect lubrication oil outlet hoses (12).
12. Remove the mounting bolts or nuts, then
remove turbochargers (13). [*1]
4 Turbocharger: 22 kg (1 piece)
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
a Replace the removed gaskets with new gas-
kets.
3 Mounting bolt: 49 ± 5 Nm {5.0 ± 0.5
kgm}
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21. WD900-3 30-29
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
(1)
REMOVAL AND INSTALLATION
OF ENGINE FRONT SEAL
SPECIAL TOOLS
REMOVAL
1. Remove the radiator. For details, see REMOVAL
AND INSTALLATION OF RADIATOR.
2. Remove mounting bolts (1), then remove
damper and crank pulley (2).
3. Take care not to damage crankshaft (3), remove
seal (4) with a screwdriver, etc.
INSTALLATION
1. Front oil seal and sleeve
1) When the seal contact face of the crank-
shaft is not worn
• Press fit the oil seal to the end of the
gear case cover by 11mm with tool A2
a Fill the space between lips on the out-
side with grease (G2-LI) up to 50 –
80%.
a Tighten the mounting bolts evenly.
2) When the seal contact face of the crank-
shaft is worn
• If the position of the oil seal can be
changed, press fit a new oil seal to a
place at which its lip does not touch the
worn groove.
a Measure the position of the worn
groove, then press fit the new oil
seal with tool A2 to a place where
there is not a worn groove.
3) When the position of the oil seal cannot be
changed
• Press fit sleeve (5) to the crankshaft.
a Remove rust and mud from sleeve
fitting portion of the crankshaft.
a Thinly apply sealant (LG-7) over the
inside of sleeve (5), then install the
sleeve to the end of crankshaft (3) in
parallel by hitting it lightly with a
wooden or plastic hammer.
Symbol
Part No. Part Name
Necessity
Q'ty
New/remodel
Sketch
A 2
795-602-2200 Installer KIT t 1
• 795-602-2210 • Installer t 1
• 795-502-2220 • Installer t 1
• 01050-32250 • Bolt t 1
• 01050-32240 • Bolt t 6
• 01640-22232 • Washer t 6
22. 30-30 WD900-3
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
(1)
a Press fit the sleeve to the depth of
5mm from the crankshaft end with
tool A2
a Press fit the sleeve by tightening the
bolts alternately.
• Press fit the seal.
a Fill the space between lips on the out-
side with grease (G2-LI) up to 50 –
80%.
a Press fit front seal (6) to the depth of
13mm with tool A2
2. Install damper and crank pulley (2).
Tighten mounting bolts (1) in the order given in
the diagram below.
a Apply engine oil (SAE-30CD) to the mount-
ing bolts.
3 Mounting bolt
1st step: 74 ± 20 Nm {7.5 ± 2.0 kgm}
2nd step: 245 – 20 Nm {25 ± 2 kgm}
3rd step: 745 – 20 Nm {76 ± 2 kgm}
a If the mounting bolts are tightened with an
impact wrench, their threads may be broken.
Accordingly, tighten them with a hand tool.
23. WD900-3 30-31
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
(1)
REMOVAL AND INSTALLATION
OF ENGINE REAR SEAL
SPECIAL TOOLS
REMOVAL
1. Remove the torque converter and transmission.
For details, see REMOVAL AND INSTALLA-
TION OF TORQUE CONVERTER AND
TRANSMISSION ASSEMBLY.
2. Remove mounting bolts (1), then remove fly-
wheel (2).
3. Taking care not to damage crankshaft (3),
remove seal (4) with a screwdriver, etc.
INSTALLATION
1. Rear oil seal and sleeve
1) When the seal contact face of the crank-
shaft is not worn
• Press fit the oil seal to the crankshaft
end by 21mm with tool A3
a Fill the space between lips on the out-
side with grease (G2-LI) up to 50 – 80%.
a Tighten the mounting bolts evenly.
2) When the seal contact face of the crank-
shaft is worn
• If the position of the oil seal can be
changed, press fit a new oil seal to a
place at which its lip does not touch the
worn groove.
a Measure the position of the worn
groove, then press fit the new oil seal
with tool A3 to a place where there is not
a worn groove.
3) When the position of the oil seal cannot be
changed
• Press fit sleeve (5) to the crankshaft.
a Remove rust and mud from sleeve fitting
portion of the crankshaft.
a Thinly apply sealant (LG-7) over the in-
side of sleeve (5), then install the sleeve
to the end of crankshaft (3) in parallel by
hitting it lightly with a wooden or plastic
hammer.
a Press fit the sleeve to the depth of 14
mm from the crankshaft end with tool A3
a Press fit the sleeve by tightening the
bolts alternately.
Symbol
Part No. Part Name
Necessity
Q'ty
New/remodel
Sketch
A
3
795-602-2300 Installer KIT t 1
• 795-602-2320 • Installer t 1
• 795-502-2120 • Sleeve t 1
• 01050-32055 • Bolt t 5
• 01050-22040 • Bolt t 5
• 01640-22032 • Washer t 10
4 795-931-1100 Puller q 1
