Komatsu WA180-3 (EU Spec) Wheel Loader Shop Manual SEBM011900 PDF

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Komatsu WA180-3 (EU Spec) Wheel Loader Shop Manual SEBM011900 – PDF DOWNLOAD

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Komatsu WA180-3 (EU Spec) Wheel Loader Shop Manual SEBM011900 – PDF DOWNLOAD 

Language : English
Pages : 547
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA180-3 (EU Spec) Wheel Loader Shop Manual SEBM011900 – PDF DOWNLOAD 

MACHINE MODEL      SERIAL NUMBER
WA180-3 (EU Spec)       53001 and up

COVER 1
CONTENTS 2
01 GENERAL 3
GENERAL ASSEMBLY DRAWING 4
SPECIFICATIONS 5
WEIGHT TABLE 8
LIST OF LUBRICANT AND WATER 9
10 STRUCTURE AND FUNCTION 11
POWER TRAIN 12
POWER TRAIN SYSTEM 13
TORQUE CONVERTER,TRANSMISSION PIPING 15
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 16
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 17
TORQUE CONVERTER 18
TORQUE CONVERTER OIL FILTER 20
TRANSMISSION 21
TRANSMISSION CONTROL VALVE 31
TRANSMISSION CONTROL 52
DRIVE SHAFT 53
AXLE 54
FINAL DRIVE 60
AXLE MOUNT 61
CENTER HINGE PIN 63
STEERING AND EMERGENCY STEERING PIPING 64
STEERING COLUMN 65
PRIORITY VALVE 66
CUSHION VALVE 69
STEERING VALVE (ORBIT-ROLL) 70
EMERGENCY STEERING PUMP 78
SECURITY VALVE 79
DIVERTER VALVE 80
OPERATION OF EMERGENCY STEERING CIRCUIT 81
BRAKE PIPING 85
BRAKE CONTROL 86
BRAKE BOOSTER 87
BRAKE 91
PARKING BRAKE CONTROL 93
PARKING BRAKE 94
HYDRAULIC PIPING 95
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM 97
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 98
HYDRAULIC TANK 99
MAIN CONTROL VALVE 102
WORK EQUIPMENT LEVER LINKAGE 115
WORK EQUIPMENT LINKAGE 116
BUCKET 118
BUCKET POSITIONER AND BOOM KICK-OUT 119
PROXIMITY SWITCH 121
ROPS CAB 123
AIR CONDITIONER 124
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM 125
ELECTRICALLY CONTROLLED SUSPENTION SYSTEM (E C S S) 132
ELECTRICAL WIRING DIAGRAM 137
ELECTRICAL CIRCUIT DIAGRAM 139
AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM 141
CENTRAL PANEL (CLUSTER GAUGE) 143
SENSOR 144
ENGINE STARTING CIRCUIT 145
ENGINE STOP CIRCUIT 146
FUEL CUT-OFF SOLENOID 147
AUTOMATIC PREHEATING CIRCUIT(Q H S CONTROLLER) 148
ELECTRICAL TRANSMISSION CONTROL 152
COMBINATION SWITCH 153
TRANSMISSION CUT-OFF FUNCTION 154
PARKING BRAKE NEUTRALIZER RELAY FUNCTION 156
KICK-DOWN SWITCH 157
KICK-DOWN ELECTRICAL CIRCUIT 158
20 TESTING AND ADJUSTING 162
STANDARD VALUE TABLE FOR ENGINE 163
STANDARD VALUE TABLE FOR CHASSIS 164
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING 167
ADJUSTING VALVE CLEARANCE 168
MEASURING COMPRESSION PRESSURE 169
TESTING AND ADJUSTING FUEL INJECTION TIMING 170
MEASURING EXHAUST COLOR 171
MEASURING BLOW-BY PRESSURE 172
MEASURING ENGINE OIL PRESSURE 173
MEASURING ENGINE SPEED 174
ADJUSTING ENGINE STOP SOLENOID 175
MEASURING ACCELERATOR PEDAL 176
MEASURING OPERATING FORCE,TRAVEL OF SPEED LEVER 178
MEASURING STALL SPEED 179
MEASURING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE 181
METHOD OF OPERATING EMERGENCY MANUAL SPOOL 183
TESTING AND ADJUSTING STEERING WHEEL 185
MEASURING STEERING OIL PRESSURE 188
MEASURING OPERATING FORCE,TRAVEL OF BRAKE PEDAL 190
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE 191
MEASURING BRAKE PERFORMANCE 193
MEASURING BRAKE OIL PRESSURE 194
TESTING FOR BRAKE DISC WEAR 195
BLEEDING AIR FROM BRAKE SYSTEM 196
MEASURING PARKING BRAKE PERFORMANCE 197
TESTING AND ADJUSTING PARKING BRAKE LINKAGE 198
TESTING PARKING BRAKE DISC WEAR 199
MEASURING PARKING BRAKE DISC WEAR 200
MEASURING WORK EQUIPMENT CONTROL LEVER 201
MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL 204
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 205
MEASURING WORK EQUIPMENT 207
TESTING AND ADJUSTING BUCKET POSITIONER 209
TESTING AND ADJUSTING BOOM KICK-OUT 210
TROUBLESHOOTING OF ENGINE SYSTEM (E MODE) 212
USING TROUBLESHOOTING CHARTS FOR ENGINE-RELATED FAILURE 213
POINTS TO REMEMBER WHEN TROUBLESHOOTING 217
E-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 218
E-2 ENGINE DOES NOT START 219
E-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 222
E-4 ENGINE STOPS DURING OPERATIONS 223
E-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 224
E-6 ENGINE LACKS OUTPUT (NO POWER) 225
E-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 226
E-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BULE) 227
E-9 OIL BECOMES CONTAMINATED QUICKLY 228
E-10 FULE CONSUMPTION IS EXCESSIVE 229
E-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 230
E-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 231
E-13 OIL LEVEL RISES 232
E-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 233
E-15 ABNORMAL NOISE IS MADE 234
E-16 VIBRATION IS EXCESSIVE 235
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (AUTO-SHIFT TRANSMISSION) (A MODE) 236
OUTLINE 237
1 FUNCTION 237
2 WHEN CARRYING OUT TROUBLESHOOTING 237
3 FAILURE CODE TABLE 237
4 TABLE OF TROUBLESHOOTING MODES AND CAUSES 238
A-1 TROUBLESHOOTING CODE [12] F SOLENOID SIGNAL SYSTEM 239
A-2 TROUBLESHOOTING CODE [13] R SOLENOID SIGNAL SYSTEM 239
A-3 TROUBLESHOOTING CODE [14] ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM 240
A-4 TROUBLESHOOTING CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM 241
A-5 TROUBLESHOOTING CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM 242
A-6 TROUBLESHOOTING CODE [21] ABNORMALITY IN GEAR SHIFT LEVER SIGNAL SYSTEM 243
A-7 TROUBLESHOOTING CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM 244
A-8 TROUBLESHOOTING CODE [23] ABNORMALITY IN ENGINE SPEED SIGNAL 245
A-9 KICK-DOWN SWITCH SYSTEM 246
A-10 TRANSMISSION CUT-OFF SIGNAL SYSTEM 247
A-11 NEUTRALIZER RELAY SIGNAL SYSTEM 248
A-12 CAUTION BUZZER SIGNAL SYSTEM 249
A-13 CONTROLLER POWER SOURCE SYSTEM 250
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM(CHASSIS RELATED) (T,S,B,H MODE) 251
POWER TRAIN 252
T-1 MACHINE DOES NOT START 252
T-2 TRAVEL SPEED IS SLOW,THRUSTING POWER IS WEAK,LACKS POWER ON SLOPES 254
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR 256
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 257
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 258
STEERING SYSTEM 259
S-1 STEERNG WHEEL DOES NOT TURN 259
S-2 STEERING IS HEAVY 260
S-3 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK 261
S-4 DEVIATES TO ONE SIDE WHEN TRAVELING 262
S-5 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT 262
S-6 EXCESSIVE SHOCK TO MACHINE WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT 262
BRAKE SYSTEM 263
B-1 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 263
B-2 BRAKE IS NOT RELEASED,BRAKE DRAGS 264
WORK EQUIPMENT 265
H-1 BOOM DOES NOT RISE 265
H-2 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER 266
H-3 WHEN BOOM IS RAISED,IT MOVES SLOWLY AT A CERTAIN HEIGHT 267
H-4 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS) 267
H-5 EXCESSIVE HYDRAULIC DRIFT OF BOOM 267
H-6 BOOM SHAKES DURING OPERATION 267
H-7 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 268
H-8 BUCKET DOES NOT TILT BACK 269
H-9 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER 270
H-10 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 271
H-11 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 271
H-12 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 271
H-13 BUCKET SHAKES DURING LOADING OPERATION(MAIN CONTROL VALVE AT HOLD) 272
H-14 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TITL 272
H-15 BOOM,BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY 273
30 DISASSEMBLY AND ASSEMBLY 274
METHOD OF USING MANUAL 276
PRECAUTIONS WHEN CARRYING OUT OPERATION 277
SPECAIL TOOL LIST 279
STARTING MOTOR 281
REMOVAL AND INSTALLATION 281
ALTERNATOR 282
REMOVAL AND INSTALLATION 282
FUEL INJECTION PUMP 283
REMOVAL 283
INSTALLATION 285
ENGINE OIL COOLER CORE 288
REMOVAL AND INSTALLATION 288
WATER PUMP 289
REMOVAL AND INSTALLATION 289
NOZZLE HOLDER 290
REMOVAL 290
INSTALLATION 291
THERMOSTAT 292
REMOVAL AND INSTALLATION 292
TURBOCHARGER 293
REMOVAL AND INSTALLATION 293
CYLINDER HEAD 294
REMOVAL 294
INSTALLATION 299
RADIATOR 302
REMOVAL 302
INSTALLATION 303
ENGINE 304
REMOVAL 304
INSTALLATION 307
TORQUE CONVERTER CHARGING PUMP 308
REMOVAL AND INSTALLATION 308
TORQUE CONVERTER,TRANSMISSION 309
REMOVAL 309
INSTALLATION 316
TORQUE CONVERTER 317
DISASSEMBLY 317
ASSEMBLY 319
TRANSMISSION 321
DISASSEMBLY 321
ASSEMBLY 332
CLUTCH PACK 347
DISASSEMBLY 347
ASSEMBLY 353
TRANSMISSION CONTROL VALVE 367
REMOVAL 367
INSTALLATION 368
DISASSEMBLY 369
ASSEMBLY 371
TRANSMISSION SOLENOID VALVE 373
DISASSEMBLY AND ASSEMLBY 373
TRANSMISSION ACCUMULATOR VALVE 374
DISASSEMBLY 374
ASSEMBLY 375
DRIVE SHAFT 376
DISASSEMBLY 376
ASSEMBLY 378
FRONT AXLE 380
REMOVAL 380
INSTALLATION 381
REAR AXLE 382
REMOVAL 382
INSTALLATION 386
DIFFERENTIAL 391
DISASSEMBLY 391
ASSEMBLY 395
AXLE HOUSING 405
DISASSEMBLY 405
ASSEMBLY 410
CENTER HINGE PIN 418
REMOVAL 418
INSTALLATION 427
PRIORITY VALVE 437
REMOVAL 437
INSTALLATION 438
STEERING VALVE 439
REMOVAL 439
INSTALLATION 441
DISASSEMBLY 442
ASSEMBLY 445
STEERING CYLINDER 450
REMOVAL 450
INSTALLATION 451
BRAKE BOOSTER 452
REMOVAL 452
INSTALLATION 454
DISASSEMBLY 455
ASSEMBLY 458
PARKING BRAKE 463
REMOVAL 463
INSTALLATION 465
HYDRAULIC TANK 466
REMOVAL 466
INSTALLATION 467
HYDRAULIC FILTER 468
REMOVAL AND INSTALLATION 468
HYDRAULIC,STEERING PUMP 469
REMOVAL 469
INSTALLATION 470
MAIN CONTROL VALVE 471
REMOVAL 471
INSTALLATION 473
DISASSEMBLY 474
ASSEMBLY 476
BUCKET CYLINDER 478
REMOVAL 478
INSTALLATION 479
BOOM CYLINDER 480
REMOVAL 480
INSTALLATION 481
HYDRAULIC CYLINDER 482
DISASSEMBLY 482
ASSEMBLY 484
WORK EQUIPMENT 486
REMOVAL 486
INSTALLATION 489
FUEL TANK 492
REMOVAL 492
INSTALLATION 493
COUNTERWEIGHT 494
REMOVAL AND INSTALLATION 494
INSTRUMENT PANEL 495
REMOVAL AND INSTALLATION 495
40 MAINTENANCE STANDARD 496
ENGINE MOUNT,TRANSMISSION MOUNT 497
TORQUE CONVERTER CHARGING PUMP 498
TORQUE CONVERTER 499
TRANSMISSION 500
TRANSMISSION CONTROL VALVE 512
ACCUMULATOR VALVE 516
DRIVE SHAFT 517
DIFFERENTIAL 518
FINAL DRIVE 521
AXLE MOUNT 523
CENTER HINGE PIN 524
STEERING COLUMN 526
PRIORITY VALVE 527
EMERGENCY STEERING PUMP 528
DIVERTER VALVE 529
SECURITY VALVE 530
STEERING CYLINDER MOUNT 531
BRAKE BOOSTER 532
BRAKE 533
PARKING BRAKE 534
HYDRAULIC PUMP 535
MAIN CONTROL VALVE 536
HYDRAULIC CYLINDER 540
WORK EQUIPMENT LINKAGE 541
BUCKET 543
BUCKET POSITIONER AND BOOM KICK-OUT 544
90 OTHERS 545
ELECTRICAL CIRCUIT DIAGRAM(1/2) 546
ELECTRICAL CIRCUIT DIAGRAM(2/2) 547

S.V 24/12/24