Komatsu WA180-3 Wheel Loader Shop Manual SEBM005802 PDF

Description

Komatsu WA180-3 Wheel Loader Shop Manual SEBM005802 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA180-3 Wheel Loader Shop Manual SEBM005802 – PDF DOWNLOAD 

Language : English
Pages : 549
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA180-3 Wheel Loader Shop Manual SEBM005802 – PDF DOWNLOAD 

SERIAL NUMBERS WA180-3 – 50001 and up

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

DESCRIPTION:

Komatsu WA180-3 Wheel Loader Shop Manual SEBM005802 – PDF DOWNLOAD 

SERIAL NUMBERS WA180-3 – 50001 and up

GENERAL PRECAUTIONS :

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

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

S.V 24/12/24