Komatsu WA180-1 LC Wheel Loader Shop Manual CEBMW17020 PDF

Description

Komatsu WA180-1 LC Wheel Loader Shop Manual CEBMW17020 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA180-1 LC Wheel Loader Shop Manual CEBMW17020 – PDF DOWNLOAD 

Language : English
Pages : 587
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu WA180-1 LC Wheel Loader Shop Manual CEBMW17020 – PDF DOWNLOAD 

MACHINE MODEL             SERIAL NUMBERS
WA180-1 LC                        75001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

TABLE OF CONTENTS:

Komatsu WA180-1 LC Wheel Loader Shop Manual CEBMW17020 – PDF DOWNLOAD 

MACHINE MODEL             SERIAL NUMBERS
WA180-1 LC                        75001 and up

MAIN MENU 0
CONTENTS 5
10 ENGINE 23
11 STRUCTURE AND FUNCTION 23
ENGINE MOUNTING 24
RADIATOR AND OIL COOLER 25
FUEL TANK AND PIPING 26
ENGINE CONTROL 27
12 TESTING AND ADJUSTING 29
STANDARD VALUE TABLE 30
SERVICE TOOL LIST 32
SAFETY PRECAUTIONS 33
EXHAUST GAS COLOR 34
ACCELERATOR PEDAL OPERATING FORCE AND ANGLE 35
OPERATING FORCE 35
OPERATING ANGLE 36
13 DISASSEMBLY AND ASSEMBLY 39
CRANKING MOTOR 40
REMOVAL 40
INSTALLATION 40
ALTERNATOR 41
REMOVAL 41
INSTALLATION 41
OIL COOLER 42
REMOVAL 42
INSTALLATION 43
WATER PUMP 44
REMOVAL 44
INSTALLATION 45
FUEL INJECTORS 46
REMOVAL 46
INSTALLATION 48
TURBOCHARGER 50
REMOVAL 50
INSTALLATION 52
CYLINDER HEAD 54
REMOVAL 54
INSTALLATION 57
RADIATOR 60
REMOVAL 60
INSTALLATION 63
ENGINE 67
REMOVAL 67
INSTALLATION 74
FUEL TANK 82
REMOVAL 82
INSTALLATION 83
20 POWER TRAIN 85
21 STRUCTURE AND FUNCTION 85
GENERAL 88
HYDRAULIC CIRCUIT FOR POWER TRAIN 90
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 91
FORWARD FIRST 92
TORQUE CONVERTER AND TRANSMISSION PIPING 94
TORQUE CONVERTER CHARGING PUMP 95
OUTLINE 95
SPECIFICATIONS 95
TORQUE CONVERTER 96
SPECIFICATIONS 96
OUTLINE 97
FLOW OF MOTIVE FORCE 97
FLOW OF OIL 97
TORQUE CONVERTER OIL FILTER 98
OPERATION 98
TORQUE CONVERTER OIL COOLER 100
OUTLINE 100
TRANSMISSION 101
OUTLINE 103
CLUTCH SHAFTS 103
FORWARD AND REVERSE CLUTCHES 103
FIRST GEAR CLUTCH 104
SECOND AND THIRD GEAR CLUTCH 104
OPERATION OF CLUTCH 105
WHEN ENGAGED 105
WHEN DISENGAGED 105
FORWARD FIRST 106
OPERATION 107
REVERSE FIRST 108
OPERATION 109
TRANSMISSION CONTROL VALVE 110
MAIN REGULATOR VALVE 112
FUNCTION 112
OPERATION 112
TORQUE CONVERTER OIL OUTLET VALVE 113
FUNCTION 113
OPERATION 113
QUICK RETURN VALVE AND ACCUMULATOR 114
FUNCTION 114
Quick Return Valve 114
Accumulator 114
OPERATION 114
When Clutch Is Engaged 114
Immediately After Gear Shifting 114
POWER MODULATING FUNCTION 116
FUNCTION 116
CLUTCH CUT-OFF VALVE 120
OPERATION 120
DRIVE SHAFTS 122
OUTLINE 122
AXLES 124
FRONT 124
REAR 125
DIFFERENTIALS 126
FRONT 126
REAR 127
TORQUE PROPORTIONING DIFFERENTIAL 128
OUTLINE 128
FUNCTION 129
OPERATION 129
FINAL DRIVES 130
OUTLINE 130
AXLE MOUNTING 132
FRONT AXLE 133
REAR AXLE 133
TIRES AND WHEELS 134
THREE PIECE WHEEL 134
ONE PIECE WHEEL 135
SPECIFICATIONS 136
22 TESTING AND ADJUSTING 137
STANDARD VALUE TABLE 138
SERVICE TOOL LIST 140
SAFETY PRECAUTIONS 140
ENGINE STALL SPEEDS 142
TORQUE CONVERTER AND TRANSMISSION OIL PRESSURES 144
TRANSMISSION SHIFT LEVERS 146
TRANSMISSION CONTROL VALVE SPOOLS 147
TROUBLESHOOTING 149
PRECAUTIONS 150
METHOD OF READING TROUBLESHOOTING TABLE 152
PREVENTING RECURRENCE OF TROUBLE 154
CHECKS BEFORE TROUBLESHOOTING 155
TROUBLESHOOTING TABLE 156
TORQUE CONVERTER AND TRANSMISSION 156
1 Machine does not move off 156
2 Machine speed is low, thrust is weak, gradeability falls off 158
3 Large shock when off or changing gear 160
4 Large time lag when moving off or changing gear 161
5 Oil temperature in torque converter is high 162
23 DISASSEMBLY AND ASSEMBLY 163
TORQUE CONVERTER CHARGING PUMP 165
REMOVAL 165
INSTALLATION 165
TORQUE CONVERTER TRANSMISSION 166
REMOVAL 166
INSTALLATION 173
TORQUE CONVERTER 180
DISASSEMBLY 180
ASSEMBLY 183
TRANSMISSION 186
DISASSEMBLY 186
ASSEMBLY 193
FORWARD REVERSE CLUTCH PACKS 204
DISASSEMBLY 204
ASSEMBLY 207
FIRST SPEED CLUTCH PACK 212
DISASSEMBLY 212
ASSEMBLY 214
SECOND AND THIRD SPEED CLUTCH PACKS 217
DISASSEMBLY 217
ASSEMBLY 219
TRANSMISSION CONTROL VALVE 224
REMOVAL 224
INSTALLATION 226
DISASSEMBLY 230
ASSEMBLY 234
DRIVE SHAFT 240
DISASSEMBLY 240
ASSEMBLY 242
FRONT AXLE 244
REMOVAL 244
INSTALLATION 246
REAR AXLE 248
REMOVAL 248
INSTALLATION 252
DIFFERENTIAL 257
DISASSEMBLY 257
ASSEMBLY 261
AXLE HOUSING 271
DISASSEMBLY 271
ASSEMBLY 277
24 MAINTENANCE STANDARD 283
TRANSMISSION AND ENGINE MOUNT 284
TORQUE CONVERTER CHARGING PUMP 286
TORQUE CONVERTER 287
TRANSMISSION 288
TRANSMISSION CLUTCH ASSEMBLY 290
FORWARD-REVERSE CLUTCH ASSEMBLY 290
1ST CLUTCH ASSEMBLY 290
2ND, 3RD CLUTCH ASSEMBLY 290
TRANSMISSION CONTROL VALVE 292
AXLE 294
DIFFERENTIAL 296
FINAL DRIVE 298
DRIVE SHAFT 299
AXLE MOUNT 300
40 STEERING SYSTEM 303
41 STRUCTURE AND FUNCTION 303
GENERAL 304
HYDRAULIC CIRCUIT FOR STEERING 305
HYDRAULIC CIRCUIT DIAGRAM FOR STEERING 306
STEERING VALVE 307
CONNECTION OF HAND PUMP AND SLEEVE 313
PRIORITY VALVE 315
STEERING CYLINDER 318
CENTER HINGE PIN 319
42 TESTING AND ADJUSTING 321
STANDARD VALUE TABLE 322
SERVICE TOOL LIST 322
STEERING WHEEL PLAY 323
OPERATING FORCE OF STEERING WHEEL 324
OPERATING TIME OF STEERING WHEEL 325
STEERING OIL PRESSURE 326
TROUBLESHOOTING 327
TROUBLESHOOTING TABLE 328
STEERING CIRCUIT 328
1 Steering wheel does not turn 328
2 Steering wheel is sluggish 329
3 Steering wheel moves unsteadily or is subjected to large shock 330
4 Machine tends to turn naturally in one particular direction when traveling 330
5 Left and right turning radii are different 330
43 DISASSEMBLY AND ASSEMBLY 331
STEERING VALVE 332
REMOVAL 332
INSTALLATION 333
DISASSEMBLY 334
ASSEMBLY 337
STEERING RELIEF VALVE 342
REMOVAL AND DISASSEMBLY 342
ASSEMBLY AND INSTALLATION 343
PRIORITY VALVE 344
REMOVAL 344
INSTALLATION 345
STEERING CYLINDER 346
REMOVAL 346
INSTALLATION 346
DISASSEMBLY 347
ASSEMBLY 349
CENTER HINGE PIN 352
REMOVAL 352
INSTALLATION 360
44 MAINTENANCE STANDARD 369
STEERING CYLINDER MOUNT 370
STEERING CYLINDER 371
CENTER HINGE PIN 372
STEERING COLUMN 374
PRIORITY VALVE 375
50 BRAKES 377
51 STRUCTURE AND FUNCTION 377
GENERAL 378
POWER MASTER CYLINDER 379
BRAKE 383
PARKING BRAKE 385
BRAKE CALIPER 386
52 TESTING AND ADJUSTING 387
STANDARD VALUE TABLE 388
TOOL LIST 389
MEASURING BRAKE PEDAL 390
BRAKE PEDAL LINKAGE 391
BRAKE PERFORMANCE 393
BRAKE OIL PRESSURE 394
BRAKE DISC WEAR 395
AIR BLEEDING FROM BRAKE CIRCUIT 396
PARKING BRAKE PERFORMANCE 397
PARKING BRAKE 398
CHECKING 398
ADJUSTING 399
MEASURING CLEARANCE 400
TROUBLESHOOTING 401
TROUBLESHOOTING TABLES 402
1 Brake is ineffective or not very effective 402
2 Brake cannot be released or drags 403
53 DISASSEMBLY AND ASSEMBLY 405
POWER MASTER CYLINDER 406
REMOVAL 406
INSTALLATION 407
DISASSEMBLY 408
ASSEMBLY 411
PARKING BRAKE 416
REMOVAL 416
INSTALLATION 418
PARKING BRAKE PAD 420
REMOVAL 420
INSTALLATION 421
54 MAINTENANCE STANDARD 423
POWER MASTER CYLINDER 424
BRAKE 425
PARKING BRAKE 426
60 WORK EQUIPMENT SYSTEM 427
61 STRUCTURE AND FUNCTION 427
GENERAL 428
HYDRAULIC CIRCUIT 430
HYDRAULIC CIRCUIT DIAGRAM 431
HYDRAULIC TANK 432
OIL FILTER BYPASS VALVE 433
BREATHER 433
HYDRAULIC AND STEERING PUMP 434
HYDRAULIC CYLINDERS 435
LIFT CYLINDER 435
DUMP CYLINDER 435
MAIN CONTROL VALVE 436
LIFT AND DUMP SPOOLS AT “HOLD POSITION” 438
LIFT SPOOL AT “RAISE POSITION” 439
LIFT SPOOL AT “LOWER POSITION” 440
LIFT SPOOL AT “FLOAT POSITION” 441
DUMP SPOOL AT “TILT BACK POSITION” 442
DUMP SPOOL AT “DUMP POSITION” 443
SAFETY VALVE (WITH SUCTION VALVE) 444
SUCTION VALVE 445
RELIEF VALVE 446
DUMP AND LIFT CONTROL LEVER LINKAGE 447
BUCKET LINKAGE 448
BUCKET POSITIONER AND BOOM KICK-OUT 450
62 TESTING AND ADJUSTING 451
STANDARD VALUE TABLE 453
TOOL LIST 454
DUMP AND LIFT CONTROL LEVERS 455
MEASURING PROCEDURE 455
ADJUSTING PROCEDURE 456
DUMP AND LIFT CONTROL VALVE SPOOL TRAVEL 457
MEASURING PROCEDURE 457
HYDRAULIC CIRCUIT FLUSHING 458
BEFORE FLUSHING 458
WORK STEPS FOR FLUSHING 459
HYDRAULIC PRESSURE 461
MEASURING PROCEDURE (Main relief valve) 461
ADJUSTING PROCEDURE (Main relief valve) 462
LIFT ARM AND BUCKET 463
MEASURING PROCEDURE 463
Lifting time of lift arm 463
Lowering time of lift arm 463
Dumping time of bucket 464
Tilt back time of bucket 464
HYDRAULIC DRIFT 465
Measuring procedure 465
BUCKET POSITIONER 466
INSPECTION PROCEDURE 466
ADJUSTING PROCEDURE 466
BOOM KICK-OUT 467
INSPECTION PROCEDURE 467
ADJUSTING PROCEDURE 467
TROUBLESHOOTING 469
LOADER CIRCUIT 470
1 Lift arm does not rise 470
2 Lilt arm moves slowly or does not have sufficient lifting power 471
3 Lift arm movement becomes slow after it reaches a certain height 472
4 Bucket cannot be held down with lift cylinder 472
5 Lift arm has large hydraulic drift 472
6 Lift arm movement is unsteady during work 472
7 Lift arm descends momentarily when the control lever is shifted from “Hold” to “Raise” 472
8 Bucket does not tilt back 473
9 Bucket moves slowly or has insufficient tilt back power 474
10 Bucket movement becomes slow during tilt beck 475
11 Bucket cannot be held down by the dump cylinder 475
12 Bucket has large hydraulic drift 475
13 Bucket moves unsteadily when machine travels under load (Main control valve in “Hold”) 475
14 Bucket dumps momentarily when control lever is shifted from “Hold” to “Tilt back” 475
15 Control levers of lift arm and bucket move stiffly and sluggishly 476
63 DISASSEMBLY AND ASSEMBLY 477
HYDRAULIC TANK 479
REMOVAL 479
INSTALLATION 480
HYDRAULIC FILTER 481
REMOVAL 481
INSTALLATION 481
HYDRAULIC-STEERING PUMP 482
REMOVAL 482
INSTALLATION 483
MAIN CONTROL VALVE 484
REMOVAL 484
INSTALLATION 486
DISASSEMBLY 489
ASSEMBLY 491
DUMP CYLINDER 492
REMOVAL 492
INSTALLATION 494
LIFT CYLINDER 495
REMOVAL 495
INSTALLATION 496
LIFT AND DUMP CYLINDER 497
DISASSEMBLY 497
ASSEMBLY 499
WORK EQUIPMENT 502
REMOVAL 502
INSTALLATION 505
COUNTERWEIGHT 508
REMOVAL 508
INSTALLATION 508
64 STRUCTURE AND FUNCTION 509
MAIN CONTROL VALVE 510
DUMP CYLINDER 512
LIFT CYLINDER 513
WORK EQUIPMENT 514
BUCKET POSITIONER AND BOOM KICK-OUT 516
BUCKET 517
HYDRAULIC AND STEERING PUMP 518
80 ELECTRIC AND ELECTRONIC SYSTEM 519
81 STRUCTURE AND FUNCTION 519
CLUSTER GAUGE 520
PROXIMITY SWITCH 521
OPERATION 522
ENGINE STARTING CIRCUIT 523
ENGINE STOP CIRCUIT 524
ELECTRICAL WIRING DIAGRAM 525
ELECTRICAL WIRING SCHEMATIC 525
SENSOR 526
BRAKE OIL LEVEL SENSOR 527
TORQUE CONVERTER OIL TEMPERATURE SENSOR 527
FUEL GAUGE SENSOR 528
COOLANT TEMPERATURE SENSOR 529
ENGINE OIL PRESSURE SENSOR 529
83 DISASSEMBLY AND ASSEMBLY 531
INSTRUMENT PANEL 532
REMOVAL 532
INSTALLATION 533
90 MISCELLANEOUS 535
91 CAB AND AIR CONDITIONER STRUCTURE AND FUNCTION 535
CAB 536
AIR CONDITIONER 538
PIPING, AIR CONDITIONER TO CONDENSER TO COMPRESSOR 538
PIPING, AIR CONDITIONER DRAIN AND HEATER LINES 540
PIPING, COOLING LINES IN REAR OF CAB 542
PIPING, SUPPLY OPENING FOR FACE AND DEFROSTER 542
PIPING DIAGRAM 543
ELECTRICAL WIRING DIAGRAM 544
AIR CONDITIONER UNIT 545
HEATING 545
COOLING 545
AIR CONDITIONER COMPRESSOR 546
AIR CONDITIONER CONDENSER 546
AIR CONDITIONER DRY RESERVOIR 547
97 GEAR PUMP – SA SERIES 549
GENERAL 550
PRINCIPLE OF OPERATION 551
MECHANISM FOR DELIVERING OIL 551
INTERNAL OIL LEAKAGE 552
FORCES ACTING ON THE GEAR 552
“TRAPPING” PHENOMENON OF THE OIL 553
PRESSURE LOADED TYPE GEAR PUMP 554
GENERAL DESCRIPTION 554
STRUCTURE AND OPERATION 555
FIXED SIDE PLATE TYPE GEAR PUMP 556
SA SERIES 557
STRUCTURE 557
FEATURES 557
SA-1 558
SA-2 558
SA-3 559
SA-4 560
TESTING AND ADJUSTING 561
DISASSEMBLY 564
Single pump 564
Tandem pump 567
Triple pump 567
ASSEMBLY 568
Single pump 568
Tandem pump 571
Triple pump 572
MAINTENANCE STANDARD 573
99 METRIC CONVERSIONS 575

S.V 15/12/24