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Komatsu WA180PT-3MC Wheel Loader Shop Manual A88001 and up – PDF DOWNLOAD
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Komatsu WA180PT-3MC Wheel Loader Shop Manual
SERIAL NUMBERS WA180PT-3MC – A88001 and UP
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Description
Komatsu WA180PT-3MC Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA180PT-3MC Wheel Loader Shop Manual
Language : English
Pages : 808
Downloadable : Yes
File Type : PDF
Size: 29.4 MB
Book Code: CEBM005201
DESCRIPTION:
Komatsu WA180PT-3MC Wheel Loader Shop 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, ADJUSTING AND TROUBLESHOOTING:
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 WA180PT-3MC Wheel Loader Shop Manual
MAIN MENU....................................................................................................... 0 COVER........................................................................................................... 1 CONTENTS........................................................................................................ 2 FOREWORD........................................................................................................ 13 SAFETY...................................................................................................... 13 SAFETY NOTICE........................................................................................... 13 IMPORTANT SAFETY NOTICE............................................................................. 13 GENERAL PRECAUTIONS................................................................................. 13 PREPARATIONS FOR WORK............................................................................... 13 PRECAUTIONS DURING WORK............................................................................. 13 GENERAL..................................................................................................... 15 HOW TO READ THE SHOP MANUAL................................................................................. 16 VOLUMES................................................................................................. 16 DISTRIBUTION AND UPDATING............................................................................... 16 FILING METHOD........................................................................................... 16 REVISED EDITION MARK.................................................................................... 16 REVISIONS............................................................................................... 16 SYMBOLS................................................................................................. 16 HOISTING INSTRUCTIONS....................................................................................... 17 HOISTING................................................................................................ 17 WIRE ROPES.............................................................................................. 17 COATING MATERIALS........................................................................................... 18 STANDARD TIGHTENING TORQUE.................................................................................. 20 STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS............................................................ 20 TIGHTENING TORQUE OF HOSE NUTS.......................................................................... 21 TIGHTENING TORQUE OF SPLIT FLANGE BOLTS................................................................. 21 TIGHTENING TORQUE FOR FLARED NUTS....................................................................... 21 ELECTRIC WIRE CODE.......................................................................................... 22 CLASSIFICATION BY THICKNESS............................................................................. 22 CLASSIFICATION BY COLOR AND CODE........................................................................ 22 CONVERSION TABLES........................................................................................... 23 METHOD OF USING THE CONVERSION TABLE.................................................................... 23 01 GENERAL...................................................................................................... 29 SPECIFICATION DRAWINGS...................................................................................... 30 BUCKET ATTACHMENT....................................................................................... 30 DIMENSIONS FOR BUCKET ATTACHMENT.................................................................... 31 FORK ATTACHMENT......................................................................................... 32 DIMENSIONS FOR FORK ATTACHMENT...................................................................... 33 MATERIAL HANDLING ARM ATTACHEMNT........................................................................ 34 DIMENSIONS FOR MATERIAL HANDLING ARM ATTACHMENT..................................................... 35 SPECIFICATION............................................................................................... 36 WEIGHT TABLE................................................................................................ 39 LIST OF LUBRICANT AND WATER................................................................................. 41 ENGINE OIL SPECIFICATIONS................................................................................... 42 NORMAL OPERATION........................................................................................ 42 ARCTIC OPERATION........................................................................................ 42 DIESEL FUEL SPECIFICATIONS.................................................................................. 43 COOLANT SPECIFICATIONS...................................................................................... 43 GENERAL................................................................................................. 43 WATER................................................................................................... 43 ANTIFREEZE.............................................................................................. 44 INHIBITORS/CONDITIONERS................................................................................. 45 10 STRUCTURE AND FUNCTION....................................................................................... 49 POWER TRAIN................................................................................................. 53 PATH OF POWER TRANSMISSION.................................................................................. 54 TORQUE CONVERTER, TRANSMISSION PIPING....................................................................... 56 TRANSMISSION HYDRAULIC SYSTEM DIAGRAM....................................................................... 58 ENGINE LOW IDLING, DIRECTIONAL LEVER AT NEUTRAL, SPEED LEVER AT 2ND..................................... 58 TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM...................................................................... 59 ENGINE STOPPED.......................................................................................... 59 TORQUE CONVERTER............................................................................................ 60 TORQUE CONVERTER OIL FILTER................................................................................. 62 TRANSMISSION................................................................................................ 64 CLUTCH.................................................................................................. 66 REVERSE 1ST CLUTCH.................................................................................. 66 FORWARD, 2ND CLUTCH................................................................................. 67 3RD, 4TH CLUTCH..................................................................................... 67 FORWARD 1ST......................................................................................... 69 FORWARD 2ND......................................................................................... 70 FORWARD 3RD......................................................................................... 71 FORWARD 4TH......................................................................................... 72 REVERSE 1ST......................................................................................... 73 TRANSMISSION CONTROL VALVE.................................................................................. 74 UPPER VALVE............................................................................................. 75 LOWER VALVE............................................................................................. 76 TRANSMISSION SOLENOID VALVE............................................................................. 77 TORQUE CONVERTER OUTLET PORT VALVE...................................................................... 78 PILOT REDUCING VALVE.................................................................................... 79 TRANSMISSION SOLENOID VALVE............................................................................. 80 PRIORITY VALVE.......................................................................................... 81 MAIN REGULATOR VALVE.................................................................................... 82 QUICK RETURN VALVE...................................................................................... 83 MODULATION FILL VALVE................................................................................... 87 DIRECTIONAL SELECTOR SPOOL.............................................................................. 89 EMERGENCY MANUAL SPOOL.................................................................................. 90 OPERATION OF FORWARD 1ST................................................................................ 92 ACCUMULATOR VALVE....................................................................................... 94 TRANSMISSION CONTROL........................................................................................ 96 DRIVE SHAFT................................................................................................. 97 AXLE........................................................................................................ 98 FRONT AXLE.............................................................................................. 98 FRONT DIFFERENTIAL...................................................................................... 99 REAR AXLE...............................................................................................100 REAR DIFFERENTIAL.......................................................................................101 TORQUE PROPORTIONING DIFFERENTIAL.......................................................................103 FINAL DRIVE.................................................................................................104 AXLE MOUNT..................................................................................................106 CENTER HINGE PIN............................................................................................108 STEERING PIPING.............................................................................................109 STEERING COLUMN.............................................................................................110 PRIORITY VALVE..............................................................................................111 CUSHION VALVE...............................................................................................114 STEERING VALVE (ORBIT-ROLL).................................................................................116 CONNECTION BETWEEN HAND PUMP AND SLEEVE.................................................................122 BRAKE.......................................................................................................124 BRAKE PIPING............................................................................................124 BRAKE CONTROL...........................................................................................125 BRAKE BOOSTER...........................................................................................126 BRAKE...................................................................................................129 PARKING BRAKE CONTROL...................................................................................131 PARKING BRAKE...........................................................................................132 HYDRAULIC...................................................................................................134 HYDRAULIC PIPING........................................................................................134 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.................................................................136 ENGINE LOW IDLING, WORK EQUIPMENT IN "HOLD".........................................................136 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM................................................................138 HYDRAULIC TANK..........................................................................................140 OIL FILTER BYPASS VALVE.............................................................................141 BREATHER............................................................................................142 PPC VALVE...............................................................................................144 PPC RELIEF VALVE........................................................................................150 ACCUMULATOR.............................................................................................151 FOR PPC VALVE.......................................................................................151 MAIN CONTROL VALVE......................................................................................152 3-SPOOL.............................................................................................152 RELIEF VALVE........................................................................................154 SAFETY VALVE (WITH SUCTION).........................................................................155 SUCTION VALVE.......................................................................................156 BOOM, BUCKET AND ATTACHMENT SPOOL AT NEUTRAL POSITION...............................................157 BOOM SPOOL AT RAISE POSITION........................................................................158 BOOM SPOOL AT LOWER POSITION........................................................................159 BOOM SPOOL AT FLOAT POSITION........................................................................160 BUCKET / FORK SPOOL AT TILT ROLL BACK POSITION......................................................161 BUCKET / FORK SPOOL AT DUMP POSITION - SLOW SPEED...................................................162 BUCKET / FORK SPOOL AT DUMP POSITION - FAST SPEED...................................................163 COUPLER PLUNGERS EXTENDED, COUPLER ATTACHED.........................................................164 COUPLER PLUNGERS RETRACTED, COUPLER REMOVAL.........................................................165 AUXILIARY ATTACHMENT PPC VALVE IN CLOSED POSITION...................................................166 AUXILIARY ATTACHMENT PPC VALVE IN OPEN POSITION.....................................................167 PILOT SOLENOID VALVE................................................................................168 WORK EQUIPMENT..............................................................................................171 WORK EQUIPMENT LEVER HYDRAULIC CONNECTIONS..............................................................171 WORK EQUIPMENT LINKAGE..................................................................................172 BUCKET..................................................................................................174 BUCKET POSITIONER AND BOOM KICK-OUT.....................................................................175 BUCKET POSITIONER...................................................................................176 BOOM KICK-OUT.......................................................................................176 PROXIMITY SWITCH....................................................................................178 ROPS CAB....................................................................................................181 AIR CONDITIONER.............................................................................................182 AIR CONDITIONER AND HEATER PIPING.......................................................................182 ECSS........................................................................................................183 ECSS HYDRAULIC AND ELECTRICAL CIRCUIT DIAGRAM...........................................................184 CENTRAL PANEL...............................................................................................186 SENSORS.....................................................................................................187 ENGINE OIL PRESSURE.....................................................................................187 BRAKE OIL LEVEL.........................................................................................187 ENGINE SPEED SENSOR.....................................................................................188 ENGINE......................................................................................................189 ENGINE STARTING CIRCUIT.................................................................................189 ENGINE STOP CIRCUIT.....................................................................................190 AUTOMATIC PREHEATING CIRCUIT................................................................................191 QUICK HEATING SYSTEM (QHS)..............................................................................191 QHS CONTROLLER..........................................................................................193 HEATER RELAY............................................................................................193 RIBBON HEATER...........................................................................................194 QHS WATER TEMPERATURE SENSOR............................................................................194 TRANSMISSION AUTO-SHIFT CONTROL.............................................................................195 TRANSMISSION AUTO-SHIFT CONTROL SYSTEM......................................................................196 SHIFT CONTROL SYSTEM FUNCTION...........................................................................197 INPUT SIGNALS.......................................................................................197 OUTPUT SIGNALS......................................................................................198 SHIFT CHARACTERISTICS...............................................................................199 SAFETY FUNCTION.....................................................................................203 TROUBLESHOOTING.........................................................................................203 TRANSMISSION CONTROLLER.................................................................................204 CONNECTOR SIGNALS...................................................................................204 COMBINATION SWITCH......................................................................................205 TRANSMISSION CUT-OFF FUNCTION...........................................................................206 PARKING BRAKE FUNCTION..................................................................................208 KICK-DOWN SWITCH........................................................................................209 KICK-DOWN ELECTRICAL CIRCUIT........................................................................210 KICK-DOWN SWITCH OPERATED...........................................................................211 KICK-DOWN SWITCH ACTUATION - CANCELED (1)...........................................................212 KICK-DOWN SWITCH ACTUATION - CANCELED (2)...........................................................213 DUMP SPEED SWITCH...........................................................................................214 QUICK COUPLER SWITCH........................................................................................215 ELECTRICAL WIRING ILLUSTRATION..............................................................................216 ELECTRICAL WIRING DIAGRAM (1/6).............................................................................217 ELECTRICAL WIRING DIAGRAM (2/6).............................................................................219 ELECTRICAL WIRING DIAGRAM (3/6).............................................................................221 ELECTRICAL WIRING DIAGRAM (4/6).............................................................................223 ELECTRICAL WIRING DIAGRAM (5/6).............................................................................225 ELECTRICAL WIRING DIAGRAM (6/6).............................................................................227 20 TESTING, ADJUSTING AND TROUBLESHOOTING.......................................................................229 STANDARD VALUE TABLE........................................................................................233 ENGINE TABLE - IN CHASSIS...............................................................................233 CHASSIS TABLE...........................................................................................234 SERVICE TOOLS TABLE.........................................................................................239 ENGINE......................................................................................................241 ADJUSTING ENGINE STOP MOTOR CABLE.......................................................................241 ADJUSTING ENGINE STOP SOLENOID..........................................................................241 MEASURING AND ADJUSTING VALVE CLEARANCE.................................................................241 MEASURING BLOW-BY PRESSURE..............................................................................241 MEASURING COMPRESSION PRESSURE..........................................................................241 MEASURING COOLANT TEMPERATURE...........................................................................241 MEASURING ENGINE LUBRICATING OIL PRESSURE...............................................................241 MEASURING ENGINE SPEEDS.................................................................................241 MEASURING EXHAUST COLOR.................................................................................241 MEASURING EXHAUST GAS TEMPRERATURE......................................................................241 MEASURING FUEL FILTER INLET RESTRICTION.................................................................241 TEST AND ADJUSTING FAN BELT TENSION.....................................................................241 TEST AND ADJUSTING FUE IN JECTIO TIMING.................................................................241 ACCELERATOR PEDAL...........................................................................................242 OPERATING FORCE.........................................................................................242 OPERATING ANGLE.........................................................................................243 SHIFT LEVER.................................................................................................244 OPERATING FORCE.........................................................................................244 TRAVEL..................................................................................................244 STALL SPEEDS................................................................................................245 TORQUE COVERTER STALL SPEED.............................................................................245 HYDRAULIC STALL SPEED ..................................................................................246 FULL STALL SPEED........................................................................................246 TORQUE CONVERTER............................................................................................247 TRANSMISSION OIL PRESSURE...................................................................................247 EMERGENCY MANUAL SPOOL......................................................................................249 OPERATION...............................................................................................249 STEERING WHEEL..............................................................................................251 PLAY....................................................................................................251 OPERATING FORCE.........................................................................................251 OPERATING TIME..........................................................................................252 STEERING OIL PRESSURE.......................................................................................253 METHOD OF MEASURING MAIN RELIF PRESSURE.................................................................253 METHOD OF ADJUSTING MAIN RELIEF PRESSURE................................................................254 BRAKE.......................................................................................................255 BRAKE PEDAL.............................................................................................255 OPERATING EFFORT....................................................................................255 TRAVEL..............................................................................................255 BRAKE PEDAL LINKAGE.....................................................................................256 TESTING.............................................................................................256 ADJUSTING...........................................................................................256 BRAKE PERFORMANCE.......................................................................................258 BRAKE OIL PRESSURE......................................................................................259 BRAKE DISC WEAR.........................................................................................260 BLEEDING AIR............................................................................................261 PARKING BRAKE...............................................................................................262 PARKING BRAKE PERFORMANCE...............................................................................262 PARKING BRAKE LINKAGE...................................................................................263 PARKING BRAKE PISTION STROKE............................................................................264 PARKING BRAKE DISC WEAR.................................................................................265 TESTING.............................................................................................265 MEASURING...........................................................................................266 WORK EQUIPMENT..............................................................................................267 PPC VALVE...............................................................................................267 MEASURING PRESSURE..................................................................................267 HYDRAULIC PRESSURE......................................................................................269 MEASUREMENT.............................................................................................272 HYDRAULIC DRIFT.........................................................................................273 BOOM KICK-OUT...........................................................................................274 BUCKET/FORK POSITIONER..................................................................................275 FUEL LEVEL SENSOR...........................................................................................277 CHECKING FOR ABNORMALITY................................................................................277 TROUBLESHOOTING GENERAL.....................................................................................279 POINTS TO REMEMBER WHEN TROUBLESHOOTING.................................................................281 SEQUENCE OF EVENTS IN TROUBLESHOOTING...................................................................283 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE...............................................................284 PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT........................................................284 HANDLING CONTROL BOX................................................................................289 POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT................................................290 CHECKS BEFORE TROUBLESHOOTING...........................................................................292 JUDGEMENT OF POWER TRAIN................................................................................293 PRECAUTIONS WHEN TROUBLESHOOTING........................................................................294 SAFETY..............................................................................................294 METHODS FOR TROUBLESHOOTING.........................................................................294 PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING.....296 PREVENTING RECURRENCE OF TROUBLE........................................................................297 HYDRAULIC EQUIPMENT.................................................................................297 OIL CHECKS......................................................................................297 CLEANING FRAGMENTS OF DAMAGED PARTS.............................................................297 METHOD OF USING TROUBLESHOOTING CHARTS..................................................................298 CATEGORY OF TROUBLESHOOTING CODE NUMBER.............................................................298 METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE.................................298 METHOD OF USING MATRIX TROUBLESHOOTING TABLES...........................................................300 METHOD OF USING ENGINE RELATED CHARTS...................................................................302 TROUBLESHOOTING ELECTRICAL CONNECTORS.......................................................................307 CONNECTOR TYPES.........................................................................................308 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..............................................................311 ELECTRICAL CIRCUIT DIAGRAMS.............................................................................319 ENGINE START, STOP SYSTEM...........................................................................319 PREHEATING SYSTEM...................................................................................320 WORK EQUIPMENT DUMP SPEED AND QUICK COUPLER SYSTEM..................................................321 TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A-MODE)..................................................323 OUTLINE.................................................................................................324 FUNCTION............................................................................................324 TROUBLESHOOTING.....................................................................................324 FAILURE CODE TABLE..................................................................................324 TABLE OF TROUBLESHOOTING MODES AND CAUSES...........................................................325 A-1 TROUBLESHOOTING CODE [12]...........................................................................326 F SOLENOID SIGNAL SYSTEM............................................................................326 A-2 TROUBLESHOOTING CODE [13]...........................................................................327 R SOLENOID SIGNAL SYSTEM............................................................................327 A-3 TROUBLESHOOTING CODE [14]...........................................................................328 ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM...........................................................328 A-4 TROUBLESHOOTING CODE [16]...........................................................................329 ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM.........................................................329 A-5 TROUBLESHOOTING CODE [20]...........................................................................330 ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM......................................................330 A-6 TROUBLESHOOTING CODE [21]...........................................................................331 ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM............................................................331 A-7 TROUBLESHOOTING CODE [22]...........................................................................332 ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM...........................................................332 A-8 TROUBLESHOOTING CODE [23]...........................................................................333 ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM...........................................................333 A-10 KICK-DOWN SWITCH SYSTEM............................................................................334 A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM.................................................................335 A-12 NEUTRALIZER RELAY SIGNAL SYSTEM....................................................................336 A-13 BUZZER SIGNAL SYSTEM...............................................................................337 A-15 CONTROLLER POWER SOURCE SYSTEM.....................................................................338 TROUBLESHOOTING ELECTRICALLY CONTROLLED SUSPENSION SYSTEM (D MODE - ECSS)...................................339 ECSS - ELECTRICAL/HYDRAULIC SCHEMATIC...................................................................340 ECSS - WORKING CHART....................................................................................340 ECSS CIRCUIT - REMAINING PRESSURE REMOVAL ..............................................................341 INSPECTION/ADJUSTMENT...............................................................................341 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...............................................................343 E-1 ENGINE DOES NOT START...............................................................................344 A. STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START.............................344 B. CHECK FUEL SHUT-OFF SOLENOID.....................................................................346 E-2 ENGINE DOES NOT STOP................................................................................347 E-4 TRANSMISSION IS NOT SET TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NOR.......348 E-10 PREHEATING IS NOT CARRIED OUT......................................................................350 E-11 PREHEATING REMAINS ACTUATED........................................................................352 E-12 ABNORMALITY IN QUICK COUPLER SYSTEM................................................................354 E-13 ABNORMALITY IN TILT CYLINDER OPERATION.............................................................355 A. ONLY SLOW DUMP SPEED IS AVAILABLE................................................................355 B. DUMP SPEED IS ERRATIC OR ONLY FAST DUMP SPEED IS AVAILABLE.......................................356 C. TILT BACK IS NOT AVAILABLE.......................................................................357 TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)...................................................................359 S-1 STARTING PERFORMANCE IS POOR........................................................................361 S-2 ENGINE DOES NOT START...............................................................................362 A. ENGINE DOES NOT TURN.............................................................................344 B. ENGINE TURNS BUT NO EXHAUST GAS COMES OUT........................................................363 C. EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START..................................................364 S-3 ENGINE DOES NOT PICK UP SMOOTHLY....................................................................365 S-4 ENGINE STOPS DURING OPERATIONS......................................................................366 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)...........................................................367 S-6 ENGINE LACKS OUTPUT (NO POWER)......................................................................368 S-7 EXHAUST GAS IS BLACK................................................................................369 S-8 OIL CONSUMPTION IS EXCESSIVE........................................................................370 S-9 OIL BECOMES CONTAMINATED QUICKLY....................................................................371 S-10 FUEL CONSUMPTION IS EXCESSIVE......................................................................372 S-11 OIL IN COOLING WATER...............................................................................373 S-12 OIL PRESSURE LAMP LIGHTS UP........................................................................374 S-13 OIL LEVEL RISES....................................................................................375 S-14 WATER TEMPERATURE BECOMES TOO HIGH.................................................................376 S-15 ABNORMAL NOISE IS MADE.............................................................................377 S-16 VIBRATION IS EXCESSIVE.............................................................................378 TROUBLESHOOTING OF HYDRAULIC & MECHANICAL SYSTEMS (T-MODE)..................................................379 POWER TRAIN.............................................................................................381 T-1 MACHINE DOES NOT START..........................................................................381 T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES............................382 T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR..........................................384 T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR.......................................385 T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH........................................................386 STEERING SYSTEM.........................................................................................387 T-6 STEERING WHEEL DOES NOT TURN....................................................................387 T-7 STEERING IS HEAVY...............................................................................388 T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK...............................................389 T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING...........................................389 BRAKE SYSTEM............................................................................................390 T-10 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...................................................390 T-11 BRAKE IS NOT RELEASED, BRAKE DRAGS.............................................................391 WORK EQUIPMENT..........................................................................................392 T-12 BOOM DOES NOT RISE.............................................................................392 T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER..............................................393 T-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT.......................................394 T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS).....................................394 T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM..............................................................394 T-17 BOOM SHAKES DURING OPERATION...................................................................395 T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE.......................395 T-19 BUCKET DOES NOT TILT BACK......................................................................396 T-20 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER...............................................397 T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION........................................398 T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER...................................................398 T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET............................................................398 T-24 BUCKET SHAKES DURING LOADING OPERATION.........................................................399 T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT......................399 T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY..................................400 TESTING, ADJUSTING AND TROUBLESHOOTING AIR CONDITIONER......................................................401 SERVICE TOOLS...........................................................................................403 GAUGE MANIFOLD......................................................................................403 STRUCTURE AND HANDLING OF GAUGE MANIFOLD........................................................404 CHARGING HOSES..................................................................................406 GAS LEAK DETECTOR...................................................................................407 HALIDE TORCH LEAK DETECTOR......................................................................407 ELECTRIC LEAK TESTER............................................................................409 VALVE FOR SERVICE CANS..............................................................................411 MAINTENANCE PROCEDURE...................................................................................412 PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING......................................................412 PROHIBITED WORK.................................................................................412 OTHER PRECAUTIONS...............................................................................412 BLEEDING AIR FROM REFRIGERATION CIRCUIT.............................................................414 PURPOSE.........................................................................................414 CONNECTING GAUGE MANIFOLD.......................................................................414 EVACUATION......................................................................................415 AIR-TIGHTNESS CHECK.............................................................................415 GAS-LEAK CHECK..................................................................................416 EVACUATION (REPEATING)..........................................................................416 CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT.................................................417 CHARGING FROM THE HIGH-PRESSURE SIDE............................................................417 CHARGING FROM THE LOW PRESSURE SIDE.............................................................418 WHEN THE AMBIENT TEMPERATURE IS LOW.............................................................419 WHEN THE AMBIENT TEMPERATURE IS HIGH............................................................419 REPLACING SERVICE CANS..............................................................................420 CHECKING THE AMOUNT OF REFRIGERANT..................................................................420 REMOVAL OF GAUGE MANIFOLD...........................................................................422 DISCHARGING THE REFRIGERANT.........................................................................422 DAILY CHECKS........................................................................................423 CHECK REFRIGERANT LEVEL.........................................................................423 CLEANING THE CONDENSER..........................................................................423 CHECKING THE V-BELT.................................................................................423 CHECKING OIL LEVEL..................................................................................424 PROCEDURE FOR CHECKING..........................................................................424 PROCEDURE FOR CHECKING OIL LEVEL................................................................424 ADDING AND REMOVING OIL.........................................................................425 ADDING OIL BY EVACUATION........................................................................425 TROUBLESHOOTING.........................................................................................426 VISUAL AND ACOUSTICAL CHECKS........................................................................426 DEFECTIVE COOLING...................................................................................427 TROUBLESHOOTING TABLE...............................................................................429 DEFECTIVE HEATING...................................................................................431 TROUBLESHOOTING USING GAUGE MANIFOLD................................................................432 PREPARATIONS BEFORE MEASURING...................................................................432 INSUFFICIENT REFRIGERANT........................................................................432 EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER......................................433 AIR INSIDE REFRIGERATION SYSTEM.................................................................434 MOISTURE IN REFRIGERATING SYSTEM................................................................435 REFRIGERANT DOES NOT CIRCULATE..................................................................436 FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE...............437 DEFECTIVE COMPRESSION BY COMPRESSOR.............................................................438 30 DISASSEMBLY AND ASSEMBLY.....................................................................................439 METHOD OF USING MANUAL......................................................................................443 PRECAUTIONS DURING OPERATION................................................................................444 PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK..............................................................444 PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK.........................................................445 PRECAUTIONS WHEN COMPLETING THE OPERATIONS..............................................................446 OTHER PRECAUTIONS.......................................................................................446 SPECIAL TOOL LIST...........................................................................................447 ENGINE COMPONENTS...........................................................................................449 ALTERNATOR ASSEMBLY.....................................................................................449 CYLINDER HEAD ASSEMBLY..................................................................................449 ENGINE OIL COOLER ASSEMBLY..............................................................................449 FUEL INJECTION PUMP ASSEMBLY............................................................................449 NOZZLE HOLDER ASSEMBLY..................................................................................449 STARTING MOTOR ASSEMBLY.................................................................................449 THERMOSTAT ASSEMBLY.....................................................................................449 TURBOCHARGER ASSEMBLY...................................................................................449 WATER PUMP ASSEMBLY.....................................................................................449 COVERS AND LADDER...........................................................................................450 REMOVAL.................................................................................................450 INSTALLATION............................................................................................451 ENGINE HOOD.................................................................................................452 REMOVAL.................................................................................................452 INSTALLATION............................................................................................453 RADIATOR....................................................................................................454 REMOVAL.................................................................................................454 INSTALLATION............................................................................................457 ENGINE......................................................................................................458 REMOVAL.................................................................................................458 INSTALLATION............................................................................................465 EXHAUST MUFFLER.............................................................................................466 REMOVAL.................................................................................................466 INSTALLATION............................................................................................466 AIR CLEANER.................................................................................................467 REMOVAL.................................................................................................467 INSTALLATION............................................................................................467 TORQUE CONVERTER CHARGING PUMP..............................................................................468 REMOVAL.................................................................................................468 INSTALLATION............................................................................................468 TORQUE CONVERTER, TRANSMISSION..............................................................................469 REMOVAL.................................................................................................469 INSTALLATION............................................................................................476 TORQUE CONVERTER............................................................................................478 DISASSEMBLY.............................................................................................478 ASSEMBLY................................................................................................480 TRANSMISSION................................................................................................482 DISASSEMBLY.............................................................................................482 DISASSEMBLY OF PARKING BRAKE........................................................................491 ASSEMBLY OF PARKING BRAKE...........................................................................493 ASSEMBLY................................................................................................496 TRANSMISSION CLUTCH PACK....................................................................................508 DISASSEMBLY.............................................................................................508 1ST, REVERSE CLUTCH.................................................................................508 FORWARD, 2ND CLUTCH PACK............................................................................510 3RD, 4TH CLUTCH PACK................................................................................512 ASSEMBLY................................................................................................514 1ST, REVERSE CLUTCH.................................................................................514 FORWARD, 2ND CLUTCH.................................................................................519 3RD, 4TH CLUTCH.....................................................................................523 TRANSMISSION CONTROL VALVE..................................................................................528 REMOVAL.................................................................................................528 INSTALLATION............................................................................................530 DISASSEMBLY.............................................................................................531 ASSEMBLY................................................................................................533 TRANSMISSION SOLENOID VALVE.................................................................................536 DISASSEMBLY.............................................................................................536 ASSEMBLY................................................................................................537 TRANSMISSION ACCUMULATOR VALVE..............................................................................538 DISASSEMBLY.............................................................................................538 ASSEMBLY................................................................................................539 DRIVE SHAFT.................................................................................................540 DISASSEMBLY.............................................................................................540 ASSEMBLY................................................................................................541 FRONT AXLE..................................................................................................542 REMOVAL.................................................................................................542 INSTALLATION............................................................................................543 REAR AXLE...................................................................................................544 REMOVAL.................................................................................................544 INSTALLATION............................................................................................548 DIFFERENTIAL................................................................................................553 DISASSEMBLY.............................................................................................553 ASSEMBLY................................................................................................557 AXLE HOUSING................................................................................................567 DISASSEMBLY.............................................................................................567 ASSEMBLY................................................................................................572 CENTER HINGE PIN............................................................................................580 REMOVAL.................................................................................................580 INSTALLATION............................................................................................588 PILOT SOLENOID VALVE........................................................................................597 REMOVAL.................................................................................................597 INSTALLATION............................................................................................597 DISASSEMBLY OF SOLENOID VALVE...........................................................................598 ASSEMBLY OF SOLENOID VALVE..............................................................................599 DISASSEMBLY OF PILOT VALVE..............................................................................600 ASSEMBLY OF PILOT VALVE.................................................................................601 PRIORITY VALVE..............................................................................................602 REMOVAL.................................................................................................602 INSTALLATION............................................................................................603 STEERING VALVE..............................................................................................604 REMOVAL.................................................................................................604 INSTALLATION............................................................................................606 DISASSEMBLY.............................................................................................607 DISASSEMBLY OF ROTOR................................................................................607 DISASSEMBLY OF CONTROL SIDE.........................................................................608 ASSEMBLY................................................................................................610 ASSEMBLY OF CONTROL SIDE............................................................................610 ASSEMBLY OF ROTOR...................................................................................612 MAIN CONTROL VALVE..........................................................................................615 REMOVAL.................................................................................................615 INSTALLATION............................................................................................617 SEPARATION OF SPOOLS....................................................................................618 ASSEMBLY OF SPOOLS......................................................................................618 ATTACHMENT SPOOL ASSEMBLY...............................................................................619 DISASSEMBLY.........................................................................................619 ASSEMBLY............................................................................................621 BUCKET DUMP SPOOL ASSEMBLY..............................................................................623 DISASSEMBLY.........................................................................................623 ASSEMBLY............................................................................................624 BOOM LIFT SPOOL.........................................................................................626 DISASSEMBLY.........................................................................................626 ASSEMBLY............................................................................................627 PPC VALVE TO MAIN CONTROL VALVE HYDRAULIC LINES.............................................................629 PPC VALVE...................................................................................................631 REMOVAL.................................................................................................631 INSTALLATION............................................................................................632 STEERING CYLINDER...........................................................................................633 REMOVAL.................................................................................................633 INSTALLATION............................................................................................635 BRAKE BOOSTER...............................................................................................636 REMOVAL.................................................................................................636 INSTALLATION............................................................................................638 DISASSEMBLY.............................................................................................639 ASSEMBLY................................................................................................642 PARKING BRAKE...............................................................................................647 REMOVAL.................................................................................................647 INSTALLATION............................................................................................649 HYDRAULIC TANK..............................................................................................651 REMOVAL.................................................................................................651 INSTALLATION............................................................................................652 HYDRAULIC FILTER............................................................................................653 REMOVAL.................................................................................................653 INSTALLATION............................................................................................653 STEERING PUMP...............................................................................................654 REMOVAL.................................................................................................654 INSTALLATION............................................................................................655 BUCKET/FORK (TILT) CYLINDERS................................................................................656 REMOVAL.................................................................................................656 INSTALLATION............................................................................................657 BOOM (LIFT) CYLINDERS.......................................................................................658 REMOVAL.................................................................................................658 INSTALLATION............................................................................................660 HYDRAULIC CYLINDER..........................................................................................661 DISASSEMBLY.............................................................................................661 ASSEMBLY................................................................................................663 ECSS SYSTEM.................................................................................................666 ECSS CIRCUIT - REMAINING PRESSURE REMOVAL...............................................................666 ECSS SOLENOID VALVE.....................................................................................667 REMOVAL.............................................................................................667 INSTALLATION........................................................................................667 ECSS CONTROL VALVE......................................................................................668 REMOVAL.............................................................................................668 INSTALLATION........................................................................................668 BOOM AND PARALLEL TOOL LINKAGE..............................................................................669 REMOVAL.................................................................................................669 INSTALLATION............................................................................................677 FUEL TANK...................................................................................................680 REMOVAL.................................................................................................680 INSTALLATION............................................................................................681 COUNTERWEIGHT...............................................................................................682 REMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS................................................................682 INSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS...........................................................682 REMOVAL OF REAR COUNTERWEIGHT...........................................................................682 INSTALLATION OF REAR COUNTERWEIGHT......................................................................683 INSTRUMENT PANEL............................................................................................684 REMOVAL.................................................................................................684 INSTALLATION............................................................................................684 AIR CONDITIONING............................................................................................685 AIR CONDITIONER UNIT....................................................................................685 REMOVAL.............................................................................................685 INSTALLATION........................................................................................691 AIR CONDITIONER CONDENSER...............................................................................692 REMOVAL.............................................................................................692 INSTALLATION........................................................................................693 DRYER RECEIVER..........................................................................................695 REMOVAL.............................................................................................695 INSTALLATION........................................................................................695 AIR CONDITIONER COMPRESSOR..............................................................................697 REMOVAL.............................................................................................697 INSTALLATION........................................................................................698 40 MAINTENANCE STANDARD.........................................................................................699 ENGINE MOUNT, TRANSMISSION MOUNT............................................................................700 TORQUE CONVERTER CHARGING PUMP..............................................................................702 TORQUE CONVERTER............................................................................................704 TRANSMISSION................................................................................................706 TRANSMISSION (1/3)......................................................................................706 TRANSMISSION (2/3)......................................................................................710 TRANSMISSION (3/3)......................................................................................714 REVERSE, 1ST CLUTCH.....................................................................................716 FORWARD, 2ND CLUTCH.....................................................................................718 3RD, 4TH CLUTCH.........................................................................................720 TRANSMISSION CONTROL VALVE..................................................................................722 UPPER VALVE.............................................................................................722 LOWER VALVE.............................................................................................724 SOLENOID VALVE..........................................................................................726 ACCUMULATOR VALVE...........................................................................................728 DRIVE SHAFT.................................................................................................730 DIFFERENTIAL................................................................................................732 DIFERENTIAL (1/2).......................................................................................732 DIFFERENTIAL (2/2)......................................................................................734 FINAL DRIVE.................................................................................................736 AXLE MOUNT..................................................................................................738 ADDITIONAL COUNTERWEIGHT....................................................................................740 CENTER HINGE PIN............................................................................................742 STEERING COLUMN.............................................................................................744 PRIORITY VALVE..............................................................................................746 STEERING CYLINDER MOUNT.....................................................................................747 BRAKE BOOSTER...............................................................................................748 BRAKE.......................................................................................................750 PARKING BRAKE...............................................................................................751 HYDRAULIC PUMP (SAL40+14+8).................................................................................752 MAIN CONTROL VALVE..........................................................................................753 3-SPOOL VALVE...........................................................................................753 HYDRAULIC CYLINDER..........................................................................................756 PPC VALVE...................................................................................................758 PILOT SOLENOID VALVE........................................................................................760 WORK EQUIPMENT LINKAGE......................................................................................762 BUCKET POSITIONER AND BOOM KICK-OUT.........................................................................766 90 OTHERS.......................................................................................................769 HYDRAULIC...................................................................................................771 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM................................................................771 BOOM, BUCKET AND ATTACHMENT SPOOL IN NEUTRAL POSITION...................................................773 BOOM SPOOL IN RAISE POSITION............................................................................775 BOOM SPOOL IN LOWER POSITION............................................................................777 BOOM SPOOL IN FLOAT POSITION............................................................................779 BUCKET / FORK SPOOL IN TILT/ROLL BACK POSITION..........................................................781 BUCKET / FORK SPOOL IN DUMP POSITION - SLOW SPEED.......................................................783 BUCKET / FORK SPOOL IN DUMP POSITION - FAST SPEED.......................................................785 COUPLER PLUNGERS EXTENDED, COUPLER ATTACHED.............................................................787 COUPLER PLUNGERS RETRACTED, COUPLER REMOVAL.............................................................789 AUXILIARY ATTACHMENT IN CLOSE POSITION..................................................................791 AUXILIARY ATTACHMENT IN OPEN POSITION...................................................................793 ELECTRICAL WIRING DIAGRAM...................................................................................795 DIAGRAM (1/6)...........................................................................................795 DIAGRAM (2/6)...........................................................................................797 DIAGRAM (3/6)...........................................................................................799 DIAGRAM (4/6)...........................................................................................801 DIAGRAM (5/6)...........................................................................................803 DIAGRAM (6/6)...........................................................................................805
KOMATSU WA180PT-3MC WHEEL LOADER SHOP MANUAL A88001 AND UP – PDF DOWNLOAD:
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