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Komatsu WA180-3 Parallel Tool Carrier Service Repair Manual SN A85001 and up – PDF DOWNLOAD
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Komatsu WA180-3 Parallel Tool Carrier Service Repair Manual
Book Code : CEBM001900
SERIAL NUMBER : WA180-3 A85001 and up
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Description
Komatsu WA180-3 Parallel Tool Carrier Service Repair Manual
FILE DETAILS:
Komatsu WA180-3 Parallel Tool Carrier Service Repair Manual
Model Specification: KOMATSU WA180-3 Parallel Tool Carrier
Language: English
File Format: PDF
Total Pages: 633
Requirements: Adobe PDF Reader
ZOOM IN/OUT: YES
Downloadable: YES
KOMATSU WA180-3 PARALLEL TOOL CARRIER SERVICE REPAIR MANUAL SN A85001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA180-3 Parallel Tool Carrier Service Repair Manual
FOREWORD:
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 judgements. 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 sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
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” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu WA180-3 Parallel Tool Carrier Service Repair Manual
MAIN MENU..................................................................................................... 0 CONTENTS...................................................................................................... 2 01 GENERAL.................................................................................................... 21 SPECIFICATION DRAWINGS.................................................................................... 22 SPECIFICATIONS............................................................................................ 28 WEIGHT TABLE.............................................................................................. 31 FUEL, COOLANT AND LUBRICANTS.............................................................................. 32 ENGINE OIL SPECIFICATIONS................................................................................. 33 DIESEL FUEL SPECIFICATIONS................................................................................ 34 COOLANT SPECIFICATIONS.................................................................................... 35 10 STRUCTURE AND FUNCTION..................................................................................... 41 POWER TRAIN............................................................................................... 43 PATH OF POWER TRANSMISSION................................................................................ 44 TORQUE CONVERTER TRANSMISSION PIPING...................................................................... 46 TORQUE CONV., TRANSMISSION HYDRAULIC SYSTEM DIAGRAM....................................................... 48 TORQUE CONV., TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM...................................................... 49 TORQUE CONVERTER.......................................................................................... 50 TORQUE CONVERTER OIL FILTER............................................................................... 52 TRANSMISSION.............................................................................................. 53 TRANSMISSION CONTROL VALVE................................................................................ 63 TRANSMISSION CONTROL...................................................................................... 84 DRIVE SHAFT............................................................................................... 85 AXLE...................................................................................................... 86 FINAL DRIVE............................................................................................... 92 AXLE MOUNT................................................................................................ 94 CENTER HINGE PIN.......................................................................................... 96 STEERING PIPING........................................................................................... 97 STEERING COLUMN........................................................................................... 98 PRIORITY VALVE ........................................................................................... 99 CUSHION VALVE.............................................................................................102 STEERING VALVE (ORBIT-ROLL)...............................................................................104 STEERING VALVE............................................................................................105 BRAKE PIPING..............................................................................................112 BRAKE CONTROL.............................................................................................113 BRAKE BOOSTER.............................................................................................114 PARKING BRAKE CONTROL.....................................................................................120 PARKING BRAKE.............................................................................................121 HYDRAULIC PIPING..........................................................................................123 STEERING, HYDRAULIC PUMP HYDRAULIC SYSTEM DIAGRAM.........................................................124 STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM ....................................................125 HYDRAULIC TANK............................................................................................127 MAIN CONTROL VALVE........................................................................................130 PILOT SOLENOID VALVE......................................................................................169 WORK EQUIPMENT LEVER LINKAGE..............................................................................172 BUCKET....................................................................................................175 BUCKET POSITIONER AND BOOM KICK-OUT.......................................................................176 ROPS CAB..................................................................................................182 AIR CONDITIONER/HEATER PIPING.............................................................................183 AIR CONDITIONER ELECTRIC CIRCUIT DIAGRAM (EAGLE)..........................................................184 ELECTRICAL WIRING ILLUSTRATION............................................................................185 ELECTRICAL WIRING DIAGRAM (1/3)...........................................................................187 ELECTRICAL WIRING DIAGRAM (2/3)...........................................................................190 ELECTRICAL WIRING DIAGRAM (3/3)...........................................................................191 CENTRAL PANEL (CLUSTER GUAGE) ............................................................................193 SENSOR....................................................................................................194 ENGINE STARTING CIRCUIT...................................................................................195 ENGINE STOP CIRCUIT.......................................................................................196 AUTOMATIC PREHEATING CIRCUIT (Q.H.S. CIRCUIT).............................................................197 ELECTRICAL TRANSMISSION CONTROL...........................................................................201 COMBINATION SWITCH........................................................................................202 TRANSMISSION CUT-OFF FUNCTION.............................................................................203 PARKING BRAKE FUNCTION....................................................................................205 KICK DOWN SWITCH..........................................................................................206 KICK DOWN ELECTRIC CIRCUIT DIAGRAM........................................................................207 DUMP SPEED SWITCH.........................................................................................212 QUICK COUPLER SWITCH......................................................................................213 20 TESTING AND ADJUSTING......................................................................................215 STANDARD VALUE TABLE FOR ENGINE...........................................................................217 STANDARD VALUE TABLE FOR CHASSIS..........................................................................218 TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING............................................................222 MEASURING ENGINE SPEEDS...................................................................................224 MEASURING ENGINE LUBRICATING OIL PRESSURE.................................................................225 MEASURING FUEL FILTER INLET RESTRICTION...................................................................225 MEASURING BLOW-BY PRESSURE................................................................................225 MEASURING COMPRESSION PRESSURE............................................................................226 MEASURING EXHAUST COLOR...................................................................................227 MEASURING COOLANT TEMPERATURE.............................................................................228 MEASURING AND ADJUSTING VALVE CLEARANCE...................................................................228 MEASURING ACCELERATOR PEDAL...............................................................................229 MEASURING OPERATING FORCE & TRAVEL OF SPEED LEVER.........................................................231 MEASURING STALL SPEEDS....................................................................................232 MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE.....................................................234 METHOD OF OPERATING EMERGENCY MANUAL SPOOL................................................................236 TESTING AND ADJUSTING STEERING WHEEL......................................................................238 MEASURING STEERING OIL PRESSURE...........................................................................240 MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL..........................................................242 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE.................................................................243 MEASURING BRAKE PERFORMANCE...............................................................................245 MEASURING BRAKE OIL PRESSURE..............................................................................246 MEASURING BRAKE DISC WEAR.................................................................................247 BLEEDING AIR FROM BRAKE SYSTEM............................................................................248 MEASURING PARKING BRAKE PERFORMANCE.......................................................................249 TESTING AND ADJUSTING PARKING BRAKE LINKAGE...............................................................250 TESTING PARKING BRAKE DISC WEAR...........................................................................251 MEASURING PARKING BRAKE DISC WEAR.........................................................................252 MEASURING WORK EQUIPMENT CONTROL LEVER....................................................................253 MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL............................................................256 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE...............................................................257 MEASURING WORK EQUIPMENT CYCLE TIMES......................................................................260 MEASURING WORK EQUIPMENT HYDRAULIC DRIFT..................................................................261 TESTING AND ADJUSTING BOOM KICK-OUT (IF EQUIPPED).........................................................262 TESTING AND ADJUSTING BUCKET / FORK POSITIONER............................................................263 ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)...............................................................265 CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR.............................................................266 TROUBLESHOOTING TABLE OF CONTENTS.........................................................................269 POINTS TO REMEMBER WHEN TROUBLESHOOTING...............................................................271 SEQUENCE OF EVENTS IN TROUBLESHOOTING.................................................................272 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.............................................................273 CHECKS BEFORE TROUBLESHOOTING.........................................................................281 HANDLING CONNECTORS...................................................................................282 PRECAUTIONS WHEN TROUBLESHOOTING......................................................................283 PREVENTING RECURRENCE OF TROUBLE......................................................................285 METHOD OF USING TROUBLESHOOTING CHARTS................................................................287 TROUBLESHOOTING OF ENGINE SYSTEM TABLE OF CONTENTS....................................................297 S-1 STARTING PERFORMANCE IS POOR (Starting always takes time).....................................298 S-2 Engine does not start.........................................................................299 S-3 Engine does not pick up smoothly (Follow up is poor)..........................................302 S-4 Engine stops during operations................................................................303 S-5 Engine does not rotate smoothly (hunting).....................................................304 S-6 Engine lacks output (no power)................................................................305 S-7 Exhaust gas is black (incomplete combustion)..................................................306 S-8 Oil consumption is excessive (or exhaust gas is blue).........................................307 S-9 Oil becomes contaminated quickly..............................................................308 S-10 Fuel consumption is excessive................................................................309 S-11 Oil is in cooling water, or water spurts back, or water level goes down......................310 S-12 Oil pressure lamp lights up (drop in oil pressure)...........................................311 S-13 Oil level rises..............................................................................312 S-14 Water temperature becomes too high (overheating).............................................313 S-15 Abnormal noise is made.......................................................................314 S-16 Vibration is excessive.......................................................................315 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) TABLE OF CONTENTS................317 POWER TRAIN.......................................................................................318 T-1 Machine does not start....................................................................318 T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes......................320 T-3 Excessive shock when starting machine or shifting gear....................................322 T-4 Excessive time lag when starting machine or shifting gear.................................323 T-5 Torque converter oil temperature is high..................................................324 STEERING SYSTEM...................................................................................325 S-1 Steering wheel does not turn..............................................................325 S-2 Steering is heavy.........................................................................326 S-3 Steering wheel shakes or there is excessive shock.........................................327 S-4 Deviates to one side when traveling.......................................................328 S-5 Turning radius is different between left and right........................................328 S-6 Excessive shock to machine when steering wheel is turned fully to left or right...........328 BRAKE SYSTEM......................................................................................329 A-1 Brakes do not work or braking effect is poor..............................................329 A-2 Brake is not released, brake drags........................................................330 WORK EQUIPMENT....................................................................................331 H-1 Boom does not rise........................................................................331 H-2 Boom movement is slow or boom lacks lifting power.........................................332 H-3 When boom is raised, it moves slowly at a certain height..................................333 H-4 Bucket cannot be pushed with boom cylinder (bucket floats)................................333 H-5 Excessive hydraulic drift of boom.........................................................333 H-6 Boom shakes during operation..............................................................333 H-7 Boom drops momentarily when control lever is operated from HOLD to RAISE..................334 H-8 Bucket does not tilt back.................................................................335 H-9 Bucket movement is slow or tilt-back lacks power..........................................336 H-10 Bucket movement becomes slow during tilt-back operation..................................337 H-11 Bucket cannot be pushed with bucket cylinder.............................................337 H-12 Excessive hydraulic drift of bucket......................................................337 H-13 Bucket shakes during loading operation (Main control valve at HOLD)......................338 H-14 Bucket dumps momentarily when control lever is operated from HOLD to TILT................338 H-15 Boom, bucket control levers are heavy or do not move smoothly............................339 H-16 Bucket dump and tilt speeds not per specification / two speed feature not functioning....340 TROUBLESHOOTING-EAGLE AIR CONDITIONER.................................................................341 30 DISASSEMBLY AND ASSEMBLY...................................................................................347 METHOD OF USING MANUAL....................................................................................349 PRECAUTIONS WHEN CARRYING OUT OPERATION...................................................................350 SPECIAL TOOL LIST.........................................................................................353 STARTING MOTOR............................................................................................355 REMOVAL AND INSTALLATION..............................................................................355 ALTERNATOR................................................................................................356 REMOVAL AND INSTALLATION..............................................................................356 FUEL INJECTION PUMP.......................................................................................357 REMOVAL...............................................................................................357 INSTALLATION..........................................................................................357 ENGINE OIL COOLER.........................................................................................358 REMOVAL AND INSTALLATION..............................................................................358 WATER PUMP................................................................................................359 REMOVAL AND INSTALLATION..............................................................................359 NOZZLE HOLDER.............................................................................................360 REMOVAL AND INSTALLATION.............................................................................360 THERMOSTAT................................................................................................361 REMOVAL AND INSTALLATION..............................................................................361 TURBOCHARGER..............................................................................................362 REMOVAL AND INSTALLATION..............................................................................362 CYLINDER HEAD.............................................................................................363 REMOVAL AND INSTALLATION..............................................................................363 RADIATOR..................................................................................................364 REMOVAL...............................................................................................364 INSTALLATION..........................................................................................367 ENGINE....................................................................................................368 REMOVAL...............................................................................................368 INSTALLATION..........................................................................................375 ENGINE HOOD...............................................................................................376 REMOVAL...............................................................................................376 INSTALLATION..........................................................................................377 EXHAUST MUFFLER...........................................................................................378 REMOVAL...............................................................................................378 INSTALLATION..........................................................................................378 AIR CLEANER...............................................................................................379 REMOVAL...............................................................................................379 INSTALLATION..........................................................................................379 TORQUE CONVERTER CHARGING PUMP............................................................................380 REMOVAL AND INSTALLATION..............................................................................380 TORQUE CONVERTER, TRANSMISSION............................................................................381 REMOVAL...............................................................................................381 INSTALLATION..........................................................................................388 TORQUE CONVERTER..........................................................................................389 DISASSEMBLY...........................................................................................389 ASSEMBLY..............................................................................................391 TRANSMISSION..............................................................................................393 DISASSEMBLY...........................................................................................393 ASSEMBLY..............................................................................................407 TRANSMISSION CLUTCH PACK..................................................................................419 DISASSEMBLY ..........................................................................................419 ASSEMBLY..............................................................................................425 TRANSMISSION CONTROL VALVE................................................................................439 REMOVAL...............................................................................................439 INSTALLATION .........................................................................................440 DISASSEMBLY...........................................................................................442 ASSEMBLY..............................................................................................444 TRANSMISSION SOLENOID VALVE...............................................................................446 DISASSEMBLY AND ASSEMBLY..............................................................................446 TRANSMISSION ACCUMULATOR VALVE............................................................................447 DISASSEMBLY...........................................................................................447 ASSEMBLY..............................................................................................448 DRIVE SHAFT...............................................................................................449 DISASSEMBLY...........................................................................................449 ASSEMBLY..............................................................................................451 FRONT AXLE................................................................................................453 REMOVAL...............................................................................................453 INSTALLATION..........................................................................................454 REAR AXLE.................................................................................................455 REMOVAL...............................................................................................455 INSTALLATION..........................................................................................459 DIFFERENTIAL..............................................................................................464 DISASSEMBLY...........................................................................................464 ASSEMBLY..............................................................................................468 AXLE HOUSING..............................................................................................478 DISASSEMBLY...........................................................................................478 ASSEMBLY..............................................................................................483 CENTER HINGE PIN..........................................................................................491 REMOVAL...............................................................................................491 INSTALLATION..........................................................................................499 PILOT SOLENOID VALVE......................................................................................508 REMOVAL...............................................................................................508 INSTALLATION..........................................................................................508 PRIORITY VALVE............................................................................................513 REMOVAL...............................................................................................513 INSTALLATION..........................................................................................514 STEERING VALVE............................................................................................515 REMOVAL...............................................................................................515 INSTALLATION..........................................................................................517 DISASSEMBLY...........................................................................................518 ASSEMBLY..............................................................................................521 MAIN CONTROL VALVE........................................................................................526 REMOVAL...............................................................................................526 INSTALLATION..........................................................................................528 DISASSEMBLY...........................................................................................529 ASSEMBLY..............................................................................................531 STEERING CYLINDER.........................................................................................533 REMOVAL...............................................................................................533 INSTALLATION..........................................................................................534 BRAKE BOOSTER.............................................................................................535 REMOVAL...............................................................................................535 INSTALLATION..........................................................................................537 DISASSEMBLY...........................................................................................538 ASSEMBLY..............................................................................................541 PARKING BRAKE.............................................................................................546 REMOVAL...............................................................................................546 INSTALLATION..........................................................................................548 HYDRAULIC TANK............................................................................................549 REMOVAL...............................................................................................549 INSTALLATION..........................................................................................550 HYDRAULIC FILTER..........................................................................................551 REMOVAL AND INSTALLATION..............................................................................551 HYDRAULIC STEERING PUMP...................................................................................552 REMOVAL...............................................................................................552 INSTALLATION..........................................................................................553 TILT CYLINDER.............................................................................................554 REMOVAL...............................................................................................554 INSTALLATION..........................................................................................556 LIFT CYLINDER.............................................................................................557 REMOVAL...............................................................................................557 INSTALLATION..........................................................................................558 HYDRAULIC CYLINDER........................................................................................559 DISASSEMBLY...........................................................................................559 ASSEMBLY..............................................................................................561 BOOM AND PARALLEL TOOL LINKAGE............................................................................563 REMOVAL...............................................................................................563 INSTALLATION..........................................................................................571 FUEL TANK.................................................................................................574 REMOVAL...............................................................................................574 INSTALLATION..........................................................................................575 COUNTERWEIGHT.............................................................................................576 REMOVAL AND INSTALLATION..............................................................................576 INSTRUMENT PANEL..........................................................................................578 REMOVAL AND INSTALLATION..............................................................................578 40 MAINTENANCE STANDARD.......................................................................................581 ENGINE MOUNT, TRANSMISSIONMOUNT...........................................................................583 TORQUE CONVERTER CHARGING PUMP............................................................................584 TORQUE CONVERTER..........................................................................................585 TRANSMISSION .............................................................................................586 TRANSMISSION CONTROL VALVE................................................................................598 ACCUMULATOR VALVE.........................................................................................602 DRIVE SHAFT...............................................................................................603 DIFFERENTIAL..............................................................................................605 FINAL DRIVE...............................................................................................608 AXLE MOUNT................................................................................................610 CENTER HINGE PIN..........................................................................................612 STEERING COLUMN...........................................................................................614 STEERING CYLINDER MOUNT...................................................................................615 PRIORITY VALVE............................................................................................616 BRAKE BOOSTER.............................................................................................617 BRAKE.....................................................................................................618 PARKING BRAKE.............................................................................................619 HYDRAULIC PUMP............................................................................................620 MAIN CONTROL VALVE........................................................................................622 2-SPOOL VALVE.........................................................................................622 3-SPOOL VALVE.........................................................................................624 PILOT SOLENOID VALVE......................................................................................626 HYDRAULIC CYLINDER........................................................................................627 WORK EQUIPMENT LINKAGE....................................................................................628 BUCKET POSITIONER AND BOOM KICK-OUT.......................................................................631 ADDITIONAL COUNTERWEIGHT..................................................................................632
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