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Description
KOMATSU WA180-1 SHOP MANUAL SEBM034906 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA180-1 SHOP MANUAL SEBM034906 – PDF DOWNLOAD
Language : English
Pages : 505
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU WA180-1 SHOP MANUAL SEBM034906 – PDF DOWNLOAD
COVER.................................................................................................... 1 CONTENTS................................................................................................. 2 10 ENGINE................................................................................................ 30 11 STRUCTRE AND FUNCTION............................................................................. 30 ENGINE MOUNT..................................................................................... 31 RADIATOR......................................................................................... 32 FUEL TAKE AND PIPING............................................................................. 33 12 TESTING AND ADJUSTING............................................................................. 34 TABLE OF JUDGEMENT STANDARD...................................................................... 35 TESTING AND ADJUSTING TOOL LIST.................................................................. 36 ADJUSTING VALVE CLEARANCE........................................................................ 37 MEASURING COMPRESSION PRESSURE................................................................... 40 TESTING AND ADJUSTING FUEL INJECTION TIMING...................................................... 41 MEASURING ENGING OIL PRESSURE AND TEMPERATURE.................................................... 42 MEASURING BLOW-BY PRESSURE....................................................................... 43 TESTING AND ADJUSTING FAN BELT TENDION........................................................... 44 MEASURING EXHAUST GAS COLOR...................................................................... 45 MEASURING OPERATING FORCE AND OPERATION ANGLE OF ACCELERATOR PEDAL............................... 46 13 DIAASSEMBLY AND ASSEMBLY.......................................................................... 48 STARTING MOTOR................................................................................... 49 REMOVAL...................................................................................... 49 INSTALLATION................................................................................. 49 ALTERNATOR....................................................................................... 50 REMOVAL...................................................................................... 50 INSTALLATION................................................................................. 50 ENGINE OIL COOLER................................................................................ 51 REMOVAL...................................................................................... 51 INSTALLATION................................................................................. 51 FUEL INJECTION PUMP.............................................................................. 52 REMOVAL...................................................................................... 52 INSTALLATION................................................................................. 53 WATER PUMP....................................................................................... 55 REMOVAL...................................................................................... 55 INSTALLATION................................................................................. 56 NOZZLE HOLDER.................................................................................... 57 REMOVAL...................................................................................... 57 INSTALLATION................................................................................. 57 TURBOCHARGER..................................................................................... 58 REMOVAL...................................................................................... 58 INSTALLATION................................................................................. 58 CYLINDER HEAD.................................................................................... 59 REMOVAL...................................................................................... 59 INSTALLATION................................................................................. 62 RADIATOR......................................................................................... 66 REMOVAL...................................................................................... 66 INSTALLATION................................................................................. 69 ENGINE........................................................................................... 72 REMOVAL...................................................................................... 72 INSTALLATION................................................................................. 78 FUEL TANK........................................................................................ 84 REMOVAL...................................................................................... 84 INSTALLATION................................................................................. 85 20 POWER TRAIN........................................................................................... 86 21 STRUCTURE AND FUNCTION............................................................................ 86 GENERAL.......................................................................................... 87 HYDRAULIC CIRCUIT FOR POWER TRAIN................................................................ 89 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN........................................................ 90 FORWARD 1ST...................................................................................... 91 TORQUE CONVERTER AND TRANSMISSION PIPING......................................................... 93 TORQUE CONVERTER CHARGING PUMP................................................................... 94 TORQUE CONVERTER................................................................................. 95 TORQUE CONVERTER OIL FILTER...................................................................... 97 TORQFLOW TRANSMISSION............................................................................ 98 CLUTCH PACK......................................................................................100 TRANSMISSION CONTROL VALVE.......................................................................105 TORUE CONVERTER OIL OUTLET VALVE.................................................................107 MIAN REGULATOR VALVE.............................................................................108 QUICK RETURN VALVE AND ACCUMULATOR...............................................................109 POWER MODULATION FUNCTION........................................................................111 ACTION OF THE CLUTCH CUT-OFF VALVE...............................................................115 DRIVE SHAFT......................................................................................117 AXLE.............................................................................................118 DIFFERENTIAL.....................................................................................120 FINAL DRIVE......................................................................................124 AXLE MOUNT.......................................................................................125 TIRE AND WHEEL...................................................................................127 22 TESTING AND ADJUSTING.............................................................................128 STANDARD VALUE TABLE.............................................................................129 TOOL LIST FOR TESTING AND ADJUSTING..............................................................130 MEASURING ENGINE STALL SPEED.....................................................................131 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION......................................133 MEASURING SHIFT LEVER............................................................................135 MEASURING VALEV SPOOL OPERATING FORCE AND TRAVEL.................................................136 TROUBLESHOOTING..................................................................................138 PRECAUTIONS WHEN TROUBLESHOOTING.............................................................139 METHOD OF READING TROUBLESHOOTING TABLE......................................................141 PREVENTING RECURRENCE OF TROUBLE.............................................................143 TROUBLESHOOTING TABLE........................................................................144 1. MACHINE DOES NOT MOVE OFF.............................................................144 2. MACHINE SPEED IS LOW, THRUST IS WEAK, GRADEABILITY FALLS OFF..........................146 3. LARGE SHOCK WHEN MOVING OFF OR CHANGING GEAR..........................................148 4. LARGE TIME LAG WHEN MOVING OFF OR CHANGING GEAR.......................................149 5. OIL TEMPERATUER IN TORQUE CONVERTER IS HIGH...........................................150 23 DISASSEMBLY AND ASSEMBLY..........................................................................151 TORQUE CONVERTER CHARGING PUMP...................................................................152 REMOVAL......................................................................................152 INSTALLATION.................................................................................152 TORQUE CONVERTER, TRANSMISSION...................................................................153 REMOVAL......................................................................................153 INSTALLATION.................................................................................160 TORQUE CONVERTER.................................................................................167 DISASSEMBLY..................................................................................167 ASSEMBLY.....................................................................................170 TRANSIMISSION....................................................................................173 DISASSEMBLY..................................................................................173 ASSEMBLY.....................................................................................180 CLUTCH PACK......................................................................................190 DISASSEMBLY..................................................................................190 ASSEMBLY.....................................................................................196 TRANSMISSION VALVE...............................................................................208 REMOVAL......................................................................................208 INSTALLATION.................................................................................210 TRANSMISSION CONTROL VALVE.......................................................................212 DISASSEMBLY..................................................................................212 ASSEMBLY.....................................................................................216 DRIVE SHAFT......................................................................................222 DISASSEMBLY..................................................................................222 ASSEMBLY.....................................................................................224 FRONT AXLE.......................................................................................226 REMOVAL......................................................................................226 INSTALLATION.................................................................................228 REAR AXLE........................................................................................230 REMOVAL......................................................................................230 INSTALLATION.................................................................................234 DIFFERENTIAL.....................................................................................239 DISASSEMBLY..................................................................................239 ASSEMBLY.....................................................................................243 AXLE HOUSING.....................................................................................253 DISASSEMBLY..................................................................................253 ASSEMBLY.....................................................................................259 24 MAINTENANCE STANDARD..............................................................................265 TANSMISSION AND ENGINE MOUNT.....................................................................266 TORQUE CONVERTER CHARGING PUMP...................................................................267 TORQUE CONVERTER.................................................................................268 TRANSMISSION.....................................................................................269 TRANSMISSION CLUTCH ASSEMBLY.....................................................................271 TRANSMISSION CONTROL VALVE.......................................................................273 AXLE.............................................................................................275 DIFFERENTIAL.....................................................................................277 FINAL DRIVE......................................................................................279 DRIVE SHAFT......................................................................................280 AXLE MOUNT.......................................................................................281 40 STEERING SYSTEM.......................................................................................283 41 STRUCTRE AND FUNCTION.............................................................................283 GENERAL..........................................................................................284 HYDRAULIC CIRCIT FOR STEERING....................................................................285 HYDRAULIC CIRCUIT DIAGRAM FOR STEERING...........................................................285 STEERING VALVE (ORBIT-ROLL VALVE)................................................................286 PRIORITY VALVE...................................................................................294 STEERING CYLINDER................................................................................297 CENTER HINGE PIN.................................................................................298 42 TESTING AND ADJUSTING.............................................................................299 STANDARD VALUE TABLE.............................................................................300 TOOL LIST FOR TESTING AND ADJUSTING..............................................................300 MEASURING STEERING WHEEL PLAY....................................................................301 STEERING OIL PRESSURE............................................................................303 TROUBLESHOOTING..................................................................................304 TROUBLESHOOTING TABLE........................................................................305 1. STEERING WHEEL DOES NOT TURN..........................................................305 2. STEERING WHEEL ID SLUGGISH............................................................306 3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK........................307 4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING............307 5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT............................................307 43 DISASSEMBLY AND ASSEMBLY..........................................................................308 STEERING VALVE...................................................................................309 REMOVAL......................................................................................309 INSTALLATION.................................................................................310 DISASSEMBLY..................................................................................311 ASSEMBLY.....................................................................................314 DOUBLE RELIEF VALVE..............................................................................318 DISASSEMBLY..................................................................................318 ASSEMBLY.....................................................................................319 PRIORITY VALVE...................................................................................320 REMOVAL......................................................................................320 INSTALLATION.................................................................................321 STEERING SYLINDER................................................................................322 REMOVAL......................................................................................322 INSTALLATION.................................................................................322 DISASSMEBLY..................................................................................323 ASSEMBLY.....................................................................................325 CENTER HINGE PIN.................................................................................328 REMOVAL......................................................................................328 INSTALLATION.................................................................................335 44 MAINTENANCE STANDARD..............................................................................343 STEERING CYLINDER MOUNT..........................................................................344 STEERING CYLINDER................................................................................345 CENTER HINGE PIN.................................................................................346 STEERING COLUMN..................................................................................348 PRIORITY VALVE...................................................................................349 50 BRAKE SYSTEM..........................................................................................350 51 STRCTURE AND FUNCTION.............................................................................350 GENERAL..........................................................................................351 POWER MASTER CYLINDER............................................................................353 BRAKE............................................................................................357 PARKING BRAKE....................................................................................359 BRAKE CALIPER....................................................................................360 52 TESTING AND ADJUSTING.............................................................................361 STANDARD VALUE TABLE.............................................................................362 TOOL LIST FOR TESTING AND ADJUSTING..............................................................363 MEASURING BRAKE PEDAL............................................................................364 TESTING AND ADJUSTING OF BRAKE PEDAL LINKAGE.....................................................365 BRAKE PERFORMANCE................................................................................367 CHECKING BRAKE OIL PRESSURE......................................................................368 MEASURING WEAR OF BRAKE DISC.....................................................................369 AIR BLEEDING FROM BRAKE LINE.....................................................................370 PARKING BRAKE PERFORMANCE........................................................................371 CHECKING AND ADJUSTING PARKING BRAKE.............................................................372 MEASURING CLEARANCE..............................................................................374 TROUBLESHOOTING..................................................................................375 TROUBLESHOOTING TABLE........................................................................376 1. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE............................................376 2. BRAKE CANNOT BE RELEASED OR DRAGS.....................................................377 53 DISASSEMLY AND ASSEMBLY...........................................................................378 POWER MASTER CYLINDER............................................................................379 REMOVAL......................................................................................379 INSTALLATION.................................................................................380 DISASSEMBLY..................................................................................381 ASSEMBLY.....................................................................................384 PARKING BRAKE....................................................................................389 REMOVAL......................................................................................389 INSTALLATION.................................................................................391 PARKING BRAKE PAD................................................................................393 REMOVAL......................................................................................393 INSTALLATION.................................................................................394 54 MAINTENANCE STANDARD..............................................................................395 POWER MASTER CYLINDER............................................................................396 BRAKE............................................................................................397 PARKING BRAKE....................................................................................398 60 WORKEQUIPMENT SYSTEM..................................................................................399 61 STRUCTRE AND FUNCTION.............................................................................399 GENERAL..........................................................................................400 HYDRAULIC CIRCUIT................................................................................401 HYDRAULIC CIRUIT DIAGRAM.........................................................................402 HYDRAULIC TANK...................................................................................403 OIL FILTER BYPASS VALVE......................................................................404 BREATHER.....................................................................................404 HYDRAULIC AND STEERING PUMP......................................................................405 HYDRAULICA CYLINDER..............................................................................406 MIAN CONTROL VALVE...............................................................................407 SAFETY VALVE.................................................................................415 SUCTION VALVE................................................................................416 RELIEF VALVE.................................................................................417 WORK EQUIPMENT LEVER LINKAGE.....................................................................418 BUCKET LINKAGE...................................................................................419 BUCKET POSITIONER AND BOOM KICK-OUT..............................................................421 62 TESTING AND ADJUSTING.............................................................................422 STANDARD VALUE TABLE.............................................................................423 TOOL LIST FOR TESTING AND ADJUSTING..............................................................424 MEASURING DUMP AND LIFT CONTROL LEVERS...........................................................425 ADJUSTING DUMP AND LIFT CONTROL LECERS...........................................................426 MEASURING THE DUMP AND LIFT CONTROL VALVE SPOOL TRAVEL...........................................427 MEASURING HYRAULIC PRESSURE......................................................................428 MEASURING LIFT ARM AND BUCKET....................................................................430 MEASURING HYDRAULIC DRIFT OF LIFT ARM AND BUCKET.................................................431 ADJUSTING BUCKET POSITIONER......................................................................432 ADJUSTING BOOM KICK-OUT..........................................................................433 TROUBLESHOOTING..................................................................................434 TROUBLESHOOTING TABLE........................................................................435 1. LIFT ARM DOES NOT RISE................................................................435 2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER.......................436 3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT......................437 4. BUCKET CANNOT BE HELD DOWN WITH LIFT CYLINDER.........................................437 5. LIFT ARM HAS LARGE HYDRAULIC DRIFT....................................................437 6. LIFTARM MOVEMENT IS UNSTEADY DURING WORK..............................................437 7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLE" TO "RAISE"....437 8. BUCKET DOES NOT TILT BACK.............................................................438 9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILE BACK POWER...............................439 10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK........................................440 11. BUCKET CANNOT BE HELD DOWN THE DUMP CYLINDER.........................................440 12. BUCKET HAS LARGE HYDRAULIC DRIFT.....................................................440 13. BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD..............................440 14. BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "TILT BACK"....440 15. CONTROL LEVERS OF LIFT ARM AND BUCKET MOVE STIFFLY AND SLUGGISHLY....................441 63 DISASSEMBLY AND ASSEMBLY..........................................................................442 HYDRAULIC TANK...................................................................................443 REMOVAL......................................................................................443 INSTALLATION.................................................................................444 HYDRAULIC FLITER.................................................................................445 REMOVAL......................................................................................445 INSTALLATION.................................................................................445 HYDRAULIS-STEERING PUMP..........................................................................446 REMOVL.......................................................................................446 INSTALLATION.................................................................................447 MAIN CONTROL VALVE...............................................................................448 REMOVAL......................................................................................448 INSTALLATION.................................................................................450 DISASSEMBLY..................................................................................452 ASSEMBLY.....................................................................................454 DUMP CYLINDER....................................................................................456 REMOVAL......................................................................................456 INSTALLATION.................................................................................457 DISASSEMBLY..................................................................................460 ASSEMBLY.....................................................................................462 LIFT CYLINDER....................................................................................458 REMOVAL......................................................................................458 INSTALLATION.................................................................................459 DISASSEMBLY..................................................................................465 ASSEMBLY.....................................................................................467 WORK EQUIPMENT...................................................................................470 REMOVAL......................................................................................470 INSTALLATION.................................................................................473 CONTERWEIGHT.....................................................................................476 REMOVAL......................................................................................476 INSTALLATION.................................................................................476 64 MAINTENANCE STANDARD..............................................................................477 MAIN CONTROL VALVE...............................................................................478 DUMP CYLINDER....................................................................................480 LIFT CYLINDER....................................................................................481 WORK EQUIPMENT...................................................................................482 BUCKET POSITIONER AND BOOM KICK-OUT..............................................................484 BUCKET...........................................................................................485 HYDRAULIC AND STEERING PUMP......................................................................486 80 ELECTRIC AND ELECTRONIC SYSTEM........................................................................487 81 STRUCTRE AND FUNCTION.............................................................................487 CLUSTER GAUGE....................................................................................488 PROXIMITY SWITCH.................................................................................489 ENGINE STARING CIRCUIT...........................................................................491 ENGINE STOP CIRCUIT..............................................................................492 PREHEATING CIRCUIT...............................................................................493 PREHEATING WITH STARTING SWITCH..............................................................493 ELECTRICAL WIRING DIAGRAM........................................................................494 ELECTRICAL WIRING DIAGRAM CIRCUIT................................................................495 83 DISASSEMBLY AND ASSEMBLY..........................................................................496 INSTRUMENT PANEL.................................................................................497 REMOVAL......................................................................................497 INSTALLATION.................................................................................498 90 OTHERS................................................................................................499 91 ELECTRICAL SYSTEM.................................................................................499 CAB..............................................................................................500 AIR CONDITIONER .................................................................................501 AIR CONDITIONER PIPING.......................................................................501 AIR CONDITIONER WIRING DIAGRAM...............................................................502 AIR CONDITIONER ELECTRIC CIRCUIT.............................................................502 AIR CONDITIONER UNIT.........................................................................503 AIR CONDITIONER COMPESSOR....................................................................504 AIR CONDITIONER DRY RESERVOIR................................................................505
DESCRIPTION:
KOMATSU WA180-1 SHOP MANUAL SEBM034906 – PDF DOWNLOAD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judge- ments. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judge- ments. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters;
these chapters are fur- ther divided into the each main group of components.
service workshop. For ease of understanding, the manual is divided into the following chapters;
these chapters are fur- ther divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an
under- standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and
mainte- nance standards.
This section explains the structure and function of each component. It serves not only to give an
under- standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and
mainte- nance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments
to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
This section explains checks to be made before and after performing repairs, as well as adjustments
to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each
com- ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of
this section may be described in STRUCTURE AND FUNCTION.
This section explains the procedures for removing, installing, disassembling and assembling each
com- ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of
this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
S.S 12/12/24
