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KOMATSU WA180-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:50001 & UP) KOMATSU WA180 3 – PDF DOWNLOAD
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- KOMATSU WA180-3 WHEEL LOADER SERVICE REPAIR MANUAL
- SERIAL NUMBER:50001 & UP
- PUBLICATION NUMBER:SEBM005802
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Description
KOMATSU WA180-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:50001 & UP) KOMATSU WA180 3
KOMATSU WA180-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:50001 & UP) KOMATSU WA180 3 – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU WA180-3 WHEEL LOADER SERVICE REPAIR MANUAL (SN:50001 & UP) KOMATSU WA180 3
- 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 chapters; these chapters are further 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 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 WHEEL LOADER SERVICE REPAIR MANUAL (SN:50001 & UP) KOMATSU WA180 3
MAIN MENU................................................................................................... 0 CONTENTS.................................................................................................... 3 01 GENERAL.................................................................................................. 24 GENERAL ASSEMBLY DRAWING................................................................................ 25 SPECIFICATIONS.......................................................................................... 26 WEIGHT TABLE............................................................................................ 29 LIST OF LUBRICANT AND WATER............................................................................. 30 10 STRUCTURE AND FUNCTION................................................................................... 32 POWER TRAIN............................................................................................. 34 POWER TRAIN SYSTEM ..................................................................................... 35 TORQUE CONVERTER, TRANSMISSION PIPING ................................................................. 37 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM .................................................................. 39 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM ................................................................ 40 TORQUE CONVERTER ....................................................................................... 41 TORQUE CONVERTER OIL FILTER ............................................................................ 43 TRANSMISSION............................................................................................ 44 TRANSMISSION CONTROL VALVE ............................................................................ 54 TRANSMISSION CONTROL.................................................................................... 75 DRIVE SHAFT............................................................................................. 76 AXLE ................................................................................................... 77 FINAL DRIVE ............................................................................................ 83 AXLE MOUNT ............................................................................................. 85 CENTER HINGE PIN ....................................................................................... 87 STEERING PIPING ........................................................................................ 88 STEERING COLUMN ........................................................................................ 89 PRIORITY VALVE ......................................................................................... 90 CUSHION VALVE........................................................................................... 93 STEERING VALVE (ORBIT-ROLL) ............................................................................ 95 BRAKE PIPING ...........................................................................................103 BRAKE CONTROL ..........................................................................................104 BRAKE BOOSTER ..........................................................................................105 BRAKE...................................................................................................109 PARKING BRAKE CONTROL ..................................................................................111 PARKING BRAKE ..........................................................................................112 HYDRAULIC PIPING .......................................................................................113 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM ................................................................115 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM ...............................................................116 HYDRAULIC TANK .........................................................................................117 MAIN CONTROL VALVE .....................................................................................121 WORK EQUIPMENT LEVER LINKAGE ...........................................................................134 WORK EQUIPMENT LINKAGE .................................................................................135 BUCKET .................................................................................................137 BUCKET POSITIONER AND BOOM KICK-OUT ....................................................................138 PROXIMITY SWITCH .......................................................................................140 CANOPY .................................................................................................142 ROPS CAB ...............................................................................................143 AIR CONDITIONER ........................................................................................144 TRAVEL DAMPER SYSTEM ...................................................................................145 ELECTRICAL WIRING DIAGRAM...............................................................................150 ELECTRICAL CIRCUIT DIAGRAM (1/2)........................................................................153 AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM (2/2)........................................................156 CENTRAL PANEL (CLUSTER GUAGE)...........................................................................157 SENSOR .................................................................................................158 ENGINE STARTING CIRCUIT ................................................................................159 ENGINE STOP CIRCUIT ....................................................................................160 AUTOMATIC PREHEATING CIRCUIT (Q.G.S. CIRCUIT) ..........................................................161 AUTOMATIC AIR BLEED MECHANISM ..........................................................................164 ELECTRICAL TRANSMISSION CONTROL .......................................................................165 COMBINATION SWITCH ....................................................................................166 TRANSMISSION CUT-OFF FUNCTION .........................................................................167 PARKING BRAKE FUNCTION .................................................................................169 KICK-DOWN SWITCH .......................................................................................170 20 TESTING AND ADJUSTING....................................................................................176 STANDARD VALUE TABLE FOR ENGINE ........................................................................177 STANDARD VALUE TABLE FOR CHASSIS .......................................................................178 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING ......................................................182 ADJUSTING VALVE CLEARANCE ..............................................................................184 MEASURING COMPRESSION PRESSURE .........................................................................185 TESTING AND ADJUSTING FUEL INJECTION TIMING ...........................................................186 MEASURING EXHAUST COLOR ................................................................................187 MEASURING BLOW-BY PRESSURE .............................................................................188 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) ......................................................189 MEASURING ENGINE OIL PRESSURE .........................................................................190 TESTING AND ADJUSTING FAN BELT TENSION ................................................................190 MEASURING ENGINE SPEED .................................................................................191 METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE .......................................................192 MEASURING ACCELERATOR PEDAL ...........................................................................194 MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER ..................................................196 MEASURING STALL SPEED ..................................................................................197 MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE ................................................199 METHOD OF OPERATING EMERGENCY MANUAL SPOOL ..........................................................201 TESTING AND ADJUSTING STEERING WHEEL .................................................................203 MEASURING STEERING OIL PRESSURE .......................................................................206 MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL .....................................................208 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE ..............................................................209 MEASURING BRAKE PERFORMANCE ...........................................................................211 MEASURING BRAKE OIL PRESSURE ...........................................................................212 TESTING FOR BRAKE DISC WEAR ............................................................................213 BLEEDING AIR FROM BRAKE SYSTEM ........................................................................214 MEASURING PARKING BRAKE PERFORMANCE ...................................................................215 TESTING AND ADJUSTING PARKING BRAKE LINKAGE .........................................................216 TESTING PARKING BRAKE DISC WEAR .......................................................................217 MEASURING PARKING BRAKE DISC WEAR ....................................................................218 MEASURING WORK EQUIPMENT CONTROL LEVER ................................................................219 MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL .....................................................222 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE .........................................................223 MEASURING WORK EQUIPMENT ..............................................................................225 TESTING AND ADJUSTING BUCKET POSITIONER ...............................................................227 TESTING AND ADJUSTING BOOM KICK-OUT ..................................................................228 TROUBLESHOOTING.........................................................................................230 TROUBLESHOOTING OF ENGINE SYSTEM....................................................................230 USING TROUBLESHOOTING CHARTS FOR ENGINE-RELATED FAILURE ......................................231 POINTS TO REMEMBER WHEN TROUBLESHOOTING ........................................................235 S-1 Starting performance is poor (Starting always takes time) ..................................236 S-2 Engine does not start ......................................................................237 S-3 Engine does not pick up smoothly (Follow-up is poor) .......................................240 S-4 Engine stops during operations .............................................................241 S-5 Engine does not rotate smoothly (hunting) ..................................................242 S-6 Engine lacks output (no power) .............................................................243 S-7 Exhaust gas is black (incomplete combustion) ...............................................244 S-8 Oil consumption is excessive (or exhaust gas is blue) ......................................245 S-9 Oil becomes contaminated quickly ...........................................................246 S-10 Fuel consumption is excessive .............................................................247 S-11 Oil is in cooling water, or water spurts back, or water level goes down ..................248 S-12 Oil pressure lamp lights up (drop in oil pressure) ........................................249 S-13 Oil level rises ...........................................................................250 S-14 Water temperature becomes too high (overheating) .........................................251 S-15 Abnormal noise is made ....................................................................252 S-16 Vibration is excessive ....................................................................253 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED)................................254 POWER TRAIN ....................................................................................255 T-1 Machine does not start .................................................................255 T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes ..................257 T-3 Excessive shock when starting machine or shifting gear .................................259 T-4 Excessive time lag when starting machine or shifting gear ..............................260 T-5 Torque converter oil temperature is high ...............................................261 STEERING SYSTEM ................................................................................262 S-1 Steering wheel does not turn ...........................................................262 S-2 Steering is heavy ......................................................................263 S-3 Steering wheel shakes or there is excessive shock ......................................264 S-4 Deviates to one side when traveling ....................................................265 S-5 Turning radius is different between left and right .....................................265 S-6 Excessive shock to machine when steering wheel is turned fully to left or right z ....265 BRAKE SYSTEM ...................................................................................266 A-1 Brakes do not work or braking effect is poor ...........................................266 A-2 Brake is not released, brake drags .....................................................267 WORK EQUIPMENT .................................................................................268 H-1 Boom does not rise .....................................................................268 H-2 Boom movement is slow or boom lacks lifting power ......................................269 H-3 When boom is raised, it moves slowly at a certain height ...............................270 H-4 Bucket cannot be pushed with boom cylinder (bucket floats) .............................270 H-5 Excessive hydraulic drift of boom ......................................................270 H-6 Boom shakes during operation ..........................................................270 H-7 Boom drops momentarily when control lever is operated’ from HOLD to RAISE .............271 H-8 Bucket does not tilt back .............................................................272 H-9 Bucket Movement is slow or tilt-back lacks power .......................................273 H-10 Bucket movement becomes slow during tilt-back operation ...............................274 H-11 Bucket cannot be pushed with bucket cylinder ..........................................274 H-12 Excessive hydraulic drift of bucket ...................................................274 H-13 Bucket shakes during loading operation (Main control valve at HOLD) ..................275 H-14 Bucket dumps momentarily when control lever is operated from HOLD to TILT ............275 H-15 Boom, bucket control levers are heavy or do not move smoothly .........................276 30 DISASSEMBLY AND ASSEMBLY.................................................................................278 METHOD OF USING MANUAL .................................................................................280 PRECAUTIONS WHEN CARRYING OUT OPERATION ................................................................281 SPECIAL TOOL LIST ......................................................................................283 STARTING MOTOR..........................................................................................285 REMOVAL AND INSTALLATION ...........................................................................285 ALTERNATOR ............................................................................................286 REMOVAL AND INSTALLATION ...........................................................................286 FUEL INJECTION PUMP.....................................................................................287 REMOVAL.............................................................................................287 INSTALLATION .......................................................................................288 ENGINE OIL COOLER ......................................................................................289 REMOVAL AND INSTALLATION ...........................................................................289 WATER PUMP ............................................................................................290 REMOVAL AND INSTALLATION ...........................................................................290 NOZZLE HOLDER..........................................................................................291 REMOVAL AND INSTALLATION ...........................................................................291 THERMOSTAT..............................................................................................292 REMOVAL AND INSTALLATION ...........................................................................292 TURBOCHARGER ...........................................................................................293 REMOVAL AND INSTALLATION............................................................................293 CYLINDER HEAD...........................................................................................294 REMOVAL.............................................................................................294 INSTALLATION .......................................................................................297 RADIATOR................................................................................................299 REMOVAL.............................................................................................299 INSTALLATION........................................................................................302 ENGINE .................................................................................................303 REMOVAL.............................................................................................303 INSTALLATION........................................................................................306 TORQUE CONVERTER CHARGING PUMP .........................................................................307 REMOVAL AND INSTALLATION ...........................................................................307 TORQUE CONVERTER, TRANSMISSION .........................................................................308 REMOVAL.............................................................................................308 INSTALLATION........................................................................................315 TORQUE CONVERTER........................................................................................316 DISASSEMBLY.........................................................................................316 ASSEMBLY ...........................................................................................318 TRANSMISSION ...........................................................................................331 DISASSEMBLY.........................................................................................320 ASSEMBLY............................................................................................331 CLUTCH PACK ...........................................................................................346 DISASSEMBLY.........................................................................................346 ASSEMBLY ...........................................................................................352 TRANSMISSION CONTROL VALVE .............................................................................366 REMOVAL.............................................................................................366 INSTALLATION........................................................................................367 DISASSEMBLY ........................................................................................369 ASSEMBLY............................................................................................371 TRANSMISSION SOLENOID VALVE ............................................................................373 DISASSEMBLY AND ASSEMBLY............................................................................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 .......................................................................................426 PRIORITY VALVE .........................................................................................435 REMOVAL.............................................................................................435 INSTALLATION........................................................................................436 STEERING VALVE .........................................................................................437 REMOVAL.............................................................................................437 INSTALLATION .......................................................................................439 DISASSEMBLY ........................................................................................440 ASSEMBLY ...........................................................................................443 STEERING CYLINDER ......................................................................................448 REMOVAL.............................................................................................448 INSTALLATION........................................................................................449 BRAKE BOOSTER ..........................................................................................450 REMOVAL.............................................................................................450 INSTALLATION .......................................................................................452 DISASSEMBLY ........................................................................................453 ASSEMBLY ...........................................................................................456 PARKING BRAKE ..........................................................................................461 REMOVAL.............................................................................................461 INSTALLATION .......................................................................................463 HYDRAULIC TANK .........................................................................................464 REMOVAL.............................................................................................464 INSTALLATION .......................................................................................465 HYDRAULIC FILTER .......................................................................................466 REMOVAL AND INSTALLATION ...........................................................................466 HYDRAULIC, STEERING PUMP ...............................................................................467 REMOVAL.............................................................................................467 INSTALLATION .......................................................................................468 MAIN CONTROL VALVE .....................................................................................469 REMOVAL.............................................................................................469 INSTALLATION........................................................................................471 DISASSEMBLY ........................................................................................473 ASSEMBLY ...........................................................................................475 BUCKET CYLINDER ........................................................................................477 REMOVAL.............................................................................................477 INSTALLATION .......................................................................................478 BOOM CYLINDER ..........................................................................................479 REMOVAL.............................................................................................479 INSTALLATION .......................................................................................480 HYDRAULIC CYLINDER......................................................................................481 DISASSEMBLY.........................................................................................481 ASSEMBLY ...........................................................................................483 WORK EQUIPMENT .........................................................................................485 REMOVAL.............................................................................................485 INSTALLATION .......................................................................................488 FUEL TANK ..............................................................................................491 REMOVAL.............................................................................................491 INSTALLATION........................................................................................492 COUNTERWEIGHT ..........................................................................................493 REMOVAL AND INSTALLATION ...........................................................................493 INSTRUMENT PANEL .......................................................................................494 REMOVAL AND INSTALLATION ...........................................................................494 40 MAINTENANCE STANDARD.....................................................................................496 ENGINE MOUNT, TRANSMISSION MOUNT .......................................................................498 TORQUE CONVERTER CHARGING PUMP .........................................................................499 TORQUE CONVERTER .......................................................................................500 TRANSMISSION............................................................................................501 TRANSMISSION CONTROL VALVE ............................................................................513 ACCUMULATOR VALVE ......................................................................................517 DRIVE SHAFT ............................................................................................518 DIFFERENTIAL............................................................................................520 FINAL DRIVE ............................................................................................523 AXLE MOUNT .............................................................................................525 CENTER HINGE PIN .......................................................................................527 STEERING COLUMN ........................................................................................529 PRIORITY VALVE .........................................................................................530 STEERING CYLINDER MOUNT ................................................................................531 BRAKE BOOSTER ..........................................................................................532 BRAKE...................................................................................................533 PARKING BRAKE...........................................................................................534 HYDRAULIC PUMP .........................................................................................535 MAIN CONTROL VALVE .....................................................................................537 HYDRAULIC CYLINDER .....................................................................................541 WORK EQUIPMENT LINKAGE .................................................................................543 BUCKET .................................................................................................545 BUCKET POSITIONER AND BOOM KICK-OUT ....................................................................546
PLEASE NOTE:
⦁ This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
⦁ This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
⦁ Require some other service manual or have any queries: please WRITE to us at [email protected]
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Jamison Cole –
Great deal at a great price.