Komatsu WA80M-8E0 Wheel Loader Shop Manual VENBM08003 PDF

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Komatsu WA80M-8E0 Wheel Loader Shop Manual VENBM08003  – PDF DOWNLOAD

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Komatsu WA80M-8E0 Wheel Loader Shop Manual VENBM08003  – PDF DOWNLOAD

Language : English
Pages : 1028
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA80M-8E0 Wheel Loader Shop Manual VENBM08003  – PDF DOWNLOAD

• Model               Serial number
  WA80M-8E0   H81431 and up

VENBM08003 WA80M-8E0 . 1
INDEX AND FOREWORD . 3
ABBREVIATION LIST 4
List of abbreviations used in the text . 4
List of abbreviations used in the circuit diagrams . 9
FOREWORD, SAFETY, BASIC INFORMATION 10
HOW TO READ THE SHOP MANUAL 10
Composition of the shop manual . 10
Symbols 12
Signal word 12
Unit . 12
SAFETY NOTICE FOR OPERATION 13
Safety matters . 13
General precautions 14
Precautions for preparatory work . 15
Precautions during work 15
Precautions for slinging work and making signals . 17
Precautions for using mobile crane . 20
Precautions for using overhead traveling crane . 20
Selecting wire ropes . 21
PRECAUTIONS TO PREVENT FIRE 23
Fire caused by fuel, oil, coolant or window washer fluid . 23
Fire caused by accumulation or attachment of flammable material 23
Fire coming from electric wiring . 23
Fire caused by piping 24
Fire around the machine due to highly heated exhaust gas . 24
Explosion caused by lighting equipment . 24
ACTIONS IF FIRE OCCURS . 25
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS . 26
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 27
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT . 28
Select an appropriate workplace 28
Disassembly and maintenance work in the field 28
Sealing of openings (prevention of flowing out of oil) . 28
Preventing intrusion of foreign materials during refilling . 29
Replacing hydraulic oil while its temperature is high 29
Avoid reusing the hydraulic oil and lubricating oil 29
Flushing operation . 29
Cleaning operation . 30
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 31
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 42
Defective contact of connectors (defective contact between male and female connectors) . 42
Defective crimping or soldering of connectors 43
Disconnection in wiring 43
Water entering the connector by high-pressure jetting 43
Entry of water, dirt, or dust when disconnecting a connector . 43
Oil, mud, or dust stuck to connector . 44
Select an appropriate workplace 45
Sealing the opening 45
How to clean parts when dirt is stuck 45
Precautions for replacing fuel filter cartridge 45
Select an appropriate workplace 46
Sealing the opening 46
PRACTICAL USE OF KOMTRAX . 47
Merit of using KOMTRAX . 47
How to make a full use of KOMTRAX 48
How to operate KOMTRAX . 48
Disconnecting connectors . 49
Connecting connectors 50
Drying wiring harness 52
Handling controller 53
Method for disconnecting Deutsch connector . 54
Method for connecting Deutsch connector 54
Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMATOME-2) 55
Method for connecting slide lock type connector (FRAMATOME-3, FRAMATOME-2) . 55
Method for disconnecting slide lock type connector (FRAMATOME-24) 55
Method for connecting slide lock type connector (FRAMATOME-24) . 56
Method for disconnecting connector with lock to pull . 57
Method for connecting connector with lock to pull 57
Method for disconnecting connector with lock to push (BOSCH-3) . 58
Method for connecting connector with lock to push (BOSCH-3) 58
Method for disconnecting connector with lock to push (AMP-3) . 59
Method for connecting connector with lock to push (AMP-3) 59
Method for disconnecting connector with lock to push (SUMITOMO-3) 59
Method for connecting connector with lock to push (SUMITOMO-3) . 59
Method for disconnecting connector with lock to push (SUMITOMO-4) 59
Method for connecting connector with lock to push (SUMITOMO-4) . 59
Method for disconnecting connector with housing to rotate 60
Method for connecting connector with housing to rotate . 60
Method for connecting ring terminals and strip fuses to power stud of printed circuit boards . 61
HOW TO READ ELECTRICAL WIRE CODE . 62
TYPE, SYMBOL, AND MATERIAL . 62
COLOR CODES TABLE 63
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 64
STANDARD DIMENSION AND TOLERANCE . 64
STANDARD CLEARANCE AND STANDARD VALUE 65
STANDARD INTERFERENCE 65
REPAIR LIMIT AND ALLOWABLE VALUE OR ALLOWABLE DIMENSION 65
ALLOWABLE CLEARANCE 66
ALLOWABLE INTERFERENCE . 66
STANDARD TIGHTENING TORQUE TABLE . 67
CONVERSION TABLE . 75
METHOD OF USING THE CONVERSION TABLE . 75
EXAMPLES OF USING THE CONVERSION TABLE TO CONVERT A UNIT FROM MM TO IN . 75
TEMPERATURE 79
SPECIFICATIONS . 81
DIMENSIONS, WEIGHTS AND OPERATING DATA . 82
SPECIFICATIONS . 84
WEIGHT TABLES 85
LUBRICANTS AND OPERATING MEDIUMS . 86
BASIC PROCEDURES OF MAINTENANCE 88
OIL 88
FUEL . 88
COOLANT 89
GREASE . 89
STORING OIL AND FUEL . 89
FILTERS 90
OUTLINE OF ELECTRIC SYSTEM . 90
TIGHTENING TORQUE LIST – METRIC SCREWS AND NUTS 91
STRUCTURE AND FUNCTION . 95
ABBREVIATION LIST 99
List of abbreviations used in the text . 99
List of abbreviations used in the circuit diagrams . 104
ELECTRICAL SYSTEM 105
BOOT-UP SYSTEM . 106
LAYOUT DRAWING OF BOOT-UP SYSTEM . 106
AROUND THE CAB AND FLOOR . 107
BATTERY DISCONNECT SWITCH 108
FUNCTION OF BATTERY DISCONNECT SWITCH 108
PREHEATING SYSTEM 110
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 111
OPERATION OF AUTOMATIC PREHEATING SYSTEM . 111
ENGINE SYSTEM 112
LAYOUT DRAWING OF ENGINE SYSTEM 112
COOLING SYSTEM . 113
LAYOUT DRAWING OF COOLING SYSTEM . 113
SPECIFICATIONS OF COOLING SYSTEM . 114
COOLING FAN CONTROL SYSTEM . 115
FUNCTION OF COOLING FAN CONTROL SYSTEM . 116
COOLING FAN REVERSE ROTATION FUNCTION (Option) . 116
COMPONENT PARTS OF COOLING SYSTEM 117
STRUCTURE OF COOLING FAN MOTOR . 117
CONTROL SYSTEM . 118
AROUND THE CAB AND FLOOR . 119
MACHINE MONITOR SYSTEM . 120
MACHINE MONITOR SYSTEM DIAGRAM . 120
KOMTRAX SYSTEM . 121
KOMTRAX SYSTEM DIAGRAM . 121
FUNCTION OF KOMTRAX SYSTEM . 121
COMPONENT PARTS OF CONTROL SYSTEM 122
MACHINE MONITOR 122
Function of KOMTRAX terminal . 132
HST CONTROLLER . 134
Structure of HST controller 134
Real time monitoring function 134
Self-diagnosis function 134
Structure of HST controller (Creep DA Option) 140
Real time monitoring function 140
Self-diagnosis function 140
CAN TERMINATING RESISTOR . 144
Function of CAN terminating resistor . 144
ENGINE CONTROLLER 145
Real time monitoring function 145
Self-diagnosis function 145
ACCELERATOR PEDAL 146
Acceleration signal 146
Idling validation signal . 146
Output Characteristics . 147
HYDRAULIC SYSTEM . 148
Structure of hydraulic tank 149
Specifications of hydraulic tank . 149
Structure of main control valve 151
POWER TRAIN SYSTEM . 154
OPERATION OF POWER TRAIN SYSTEM 155
FUNCTION OF THE CLOSED CIRCUIT SYSTEM 157
SPECIFICATIONS OF THE HST SYSTEM . 157
STRUCTURE OF THE HST SYSTEM 158
20km/h STD DA (with and without Speed Control) . 158
20km/h or 40km/h with Speed Control and ET Pump 159
COMPONENT PARTS OF POWER TRAIN SYSTEM 160
Structure of drive shaft . 160
Function of drive shaft 160
Structure of HST pump 161
Operation of HST pump 163
Components of HST pump . 164
HST motor 168
Structure of transfer box 170
Function of transfer box . 171
Structure of front axle 172
Structure of rear axle . 173
Function of differential . 175
Function of towing system 177
WORK EQUIPMENT SYSTEM 178
Layout of work equipment system 178
WORK EQUIPMENT LOCK SYSTEM . 180
ECSS (Option) 181
Function of ECSS . 181
Operation of ECSS 181
RETURN TO DIG (option) . 182
Structure 182
Function . 182
Main control valve . 183
Emergency lowering . 183
Loader Linkage with quick-coupler 185
STEERING SYSTEM 187
STEERING COLUMN 188
Structure of steering column . 188
General view . 188
PRIORITY VALVE . 191
ORBITROL-VALVE . 192
STEERING RELIEF VALVE 193
BRAKE SYSTEM . 194
LAYOUT DRAWING OF BRAKE SYSTEM . 194
SERVICE BRAKE ASSEMBLY . 195
Inching Function . 195
PARKING BRAKE ASSEMBLY . 197
STRUCTURE OF BRAKE SYSTEM 197
UNDERCARRIAGE AND FRAME 198
Rear axle mount 199
Frame, axle mount and center hinge pin . 200
TIRE . 201
Structure of radial tire . 201
General view . 201
Structure 201
Structure of bias tire . 202
General view . 202
Structure 202
WORK EQUIPMENT . 203
STRUCTURE OF WORK EQUIPMENT 203
STRUCTURE OF BUCKET 204
General view and sectional view 204
CAB AND ITS ATTACHMENTS 205
ROPS FOPS CAB 205
Structure of ROPS FOPS cab . 205
Function of ROPS FOPS cab 206
CAB MOUNT 207
Structure of cab mount . 207
General view . 207
Function of cab mount 207
STANDARD VALUE TABLE . 219
ABBREVIATION LIST 220
List of abbreviations used in the text . 220
List of abbreviations used in the circuit diagrams . 225
STANDARD VALUE TABLE . 226
Standard value table for engine 226
Standard value table for chassis . 227
TEST CERTIFICATE . 229
TESTING AND ADJUSTING 231
ABBREVIATION LIST 235
List of abbreviations used in the text . 235
List of abbreviations used in the circuit diagrams . 241
TEST ENGINE WITH SOFTWARE TOOL . 242
CONNECTION OF A COMPUTER TO THE MACHINE 242
ENGINE AND COOLING SYSTEM 244
TEST ENGINE SPEED 244
Method for testing engine speed 244
Method for testing engine low idle speed . 244
Method for testing engine high idle speed 245
Method for testing engine speed HST stall 246
Method for testing engine speed at hydraulic stall . 247
Method for testing engine speed at full stall (HST stall and hydraulic stall) 248
TEST EXHAUST GAS COLOUR 250
Testing tool for exhaust gas colour 250
METHOD FOR TESTING EXHAUST GAS COLOUR BY HANDY SMOKE CHECKER . 252
TEST AND ADJUST VALVE CLEARANCE 253
METHOD FOR TESTING AND ADJUSTINGVALVE CLEARANCE 254
TEST COMPRESSION PRESSURE 255
METHOD FOR TESTING COMPRESSION PRESSURE 255
Compression pressure inspection procedures . 256
Injector reassembly procedures . 257
TEST ENGINE OIL PRESSURE . 258
METHOD FOR TESTING ENGINE OIL PRESSURE . 258
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM . 259
TEST FUEL CIRCUIT FOR LEAKAGE 260
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 260
Testing method of fuel circuit for leakage at engine stopped . 260
Testing method of fuel circuit for leakage at engine low idle 261
Testing method of fuel circuit for leakage at engine high idle . 261
HANDLE NO-INJECTION CRANKING OPERATION . 262
TEST DOC AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 263
METHOD FOR TESTING DOC AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 263
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 264
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS . 264
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 265
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 265
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 266
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 266
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT . 267
TEST ALTERNATOR BELT . 268
METHOD FOR TESTING ALTERNATOR BELT . 268
POWER TRAIN 269
TEST AND ADJUST HST PRESSURE CUT OFF . 269
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE . 271
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE . 271
STEERING SYSTEM 272
Operating time for steering wheel 272
Operating force of steering wheel 273
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 274
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE . 275
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE . 276
BLEED AIR FROM STEERING CYLINDER CIRCUIT . 277
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT . 277
BLEED AIR FROM BRAKE CIRCUIT . 278
TEST BRAKING PERFORMANCE . 280
MEASURING THE STOPPING DISTANCE 280
TEST AND ADJUST BRAKE PEDAL 281
TEST WEAR OF WHEEL BRAKE DISC 282
TEST PARKING BRAKE PERFORMANCE . 283
HYDRAULIC SYSTEM . 284
Release the remaining pressure from small accumulator for gear switching and safety valves (option) 284
Releasing the remaining pressure in ECSS . 286
TEST AND ADJUST WORK EQUIPMENT PRESSURE 287
TEST BOOST PRESSURE 288
TESTING AND ADJUSTING COOLING FAN SPEED 289
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE 291
METHOD FOR TESTING THE ECSS ACCUMULATOR NITROGEN GAS PRESSURE 292
METHOD FOR CHARGING THE ECSS ACCUMULATOR WITH NITROGEN GAS . 293
ELECTRICAL SYSTEM 295
SET AND ADJUST EACH EQUIPMENT 295
SET AND OPERATE MACHINE MONITOR 296
Switch panel . 296
Operator mode and service mode of machine monitor 297
OPERATOR MODE 299
Setting usage limitation (password) 299
Change password 300
SERVICE MODE . 302
METHOD FOR OPERATING SERVICE MODE 302
Table of self-define monitoring 305
ABNORMALITY RECORD MENU 314
DEFAULT MENU . 325
METHOD FOR SETTING WITH DEFAULT SETTING MENU (OPTION SELECTION) 327
ADJUSTMENT MENU 330
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (T/C DEVICE CALIBRATION) . 330
HANDLE BATTERY DISCONNECT SWITCH . 333
TEST DIODES 335
TROUBLESHOOTING 337
ABBREVIATION LIST 341
List of abbreviations used in the text . 341
List of abbreviations used in the circuit diagrams . 347
RELATED INFORMATION ON TROUBLESHOOTING . 348
GENERAL TROUBLESHOOTING POINTS . 348
SEQUENCE OF EVENTS IN TROUBLESHOOTING 350
CHECKS BEFORE TROUBLESHOOTING 352
Engine, lubricating oil and coolant 352
Hydraulic and mechanical equipment . 352
Electric equipment . 353
Exterior . 353
Interior . 353
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 354
WALK-AROUND CHECK 354
PROCEDURE FOR TESTING AND TROUBLESHOOTING 356
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE . 357
CONNECTOR LOCATION LIST 359
CONNECTOR CONTACT IDENTIFICATION . 368
SPARE FUSES AND RELAY 405
USB socket on central electric board (CEB) . 410
FAILURE CODES TABLE 413
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF HST-CONTROLLER CODE) . 435
POWER ON . 436
8.2.1 Documentation of Power On (PwrOn) 436
8.2.1 – 2 Interface 436
8.2.1 – 3 Description 437
8.2.1 – 3.3 State 2: Check sensor supply voltages 440
8.2.1 – 3.4 State 3: Check hardware monitoring errors 440
8.2.1 – 3.5 State 4: Check first application specific start condition 440
8.2.1 – 3.6 State 5: Check central switch 440
8.2.1 – 3.7 State 6: Configure safouts . 441
8.2.1 – 3.8 State 7: Check safouts . 441
8.2.1 – 3.9 State 8: Check diesel engine speed . 441
8.2.1 – 3.10 State 9: Enable sensor supply monitoring 442
8.2.1 – 3.11 State 10: Check hardware monitoring errors 442
8.2.1 – 3.12 State 11: Check second applications specific start condition 442
8.2.1 – 3.12 State 11: Check second applications specific start condition 442
8.2.1 – 3.13 State 12: Run . 442
8.2.1 – 3.14 Diagnosis Configuration Notes . 443
8.2.1 – 4 Input Signals 443
8.2.1 – 5 Parameters . 444
8.2.1 – 6 Output Signals . 444
8.2.1 – 7 Error Information 444
Abbreviations for Failure Code (HST-controller) 446
FAILURE CODE (#R0CIB) 447
FAILURE CODE (#R0CKB) 448
FAILURE CODE (#R0CLB) 449
FAILURE CODE (#R0CMB) 450
FAILURE CODE (#R0CPV) 451
FAILURE CODE (#R0CQB) 452
FAILURE CODE (#R0CRB) 453
FAILURE CODE (#R0CSB) 454
FAILURE CODE (#R0CTB) 455
FAILURE CODE (#R0CWB) 456
FAILURE CODE (#R0JLB) 457
FAILURE CODE (#R0JMB) 458
FAILURE CODE (#R0JNB) 459
FAILURE CODE (#R0JOB) 460
FAILURE CODE (#R0JPB) 461
FAILURE CODE (#R0QR2) 462
FAILURE CODE (#R0QS2) 463
FAILURE CODE (#R0QT4) 464
FAILURE CODE (#R0QU3) 465
FAILURE CODE (#R0QV4) 466
FAILURE CODE (#R0QY4) 467
FAILURE CODE (#R0QZ4) 468
FAILURE CODE (#R0R0V) 469
FAILURE CODE (#R0R1V) 470
FAILURE CODE (#R0SHV) 471
FAILURE CODE (#R0SJV) 472
FAILURE CODE (#R0SLV) 473
FAILURE CODE (#R0XU2) 474
FAILURE CODE (#R0XU3) 475
FAILURE CODE (#R0XU4) 476
FAILURE CODE (#R0XUB) 477
FAILURE CODE (#R0XV2) 478
FAILURE CODE (#R0XV3) 479
FAILURE CODE (#R0XV4) 480
FAILURE CODE (#R0XVB) 481
FAILURE CODE (#R0XW2) 482
FAILURE CODE (#R0XW3) 483
FAILURE CODE (#R0XW4) 484
FAILURE CODE (#R0XWB) 485
FAILURE CODE (#R14W2) 486
FAILURE CODE (#R14WB) 487
FAILURE CODE (#R14X2) 488
FAILURE CODE (#R14XB) 489
FAILURE CODE (#R14Y2) 490
FAILURE CODE (#R14YB) 491
FAILURE CODE (#R14Z2) 492
FAILURE CODE (#R14ZB) 493
FAILURE CODE (#R1502) 494
FAILURE CODE (#R1504) 495
FAILURE CODE (#R150B) 496
FAILURE CODE (#R1512) 497
FAILURE CODE (#R151B) 498
FAILURE CODE (#R15C2) 499
FAILURE CODE (#R15C3) 500
FAILURE CODE (#R15C4) 501
FAILURE CODE (#R15CB) 502
FAILURE CODE (#R15CV) 503
FAILURE CODE (#R1KWJ) 504
FAILURE CODE (#R1KWV) 505
FAILURE CODE (#R1L0B) 506
FAILURE CODE (#R1L2B) 507
FAILURE CODE (#R1L4V) 508
FAILURE CODE (#R1QB2) 509
FAILURE CODE (#R1QBB) 510
FAILURE CODE (#R1QBV) 511
FAILURE CODE (#R1QD2) 512
FAILURE CODE (#R1QDB) 513
FAILURE CODE (#R1QE2) 514
FAILURE CODE (#R1QEB) 515
FAILURE CODE (#R1QEV) 516
FAILURE CODE (#R1XEB) 517
FAILURE CODE (#R1XFB) 518
FAILURE CODE (#R1XG2) 519
FAILURE CODE (#R1XGB) 520
FAILURE CODE (#R1XJB) 521
FAILURE CODE (#R20XB) 522
FAILURE CODE (#R20YB) 523
FAILURE CODE (#R268B) 524
FAILURE CODE (#R2693) 525
FAILURE CODE (#R2694) 526
FAILURE CODE (#R2695) 527
FAILURE CODE (#R269B) 528
FAILURE CODE (#R26AB) 529
FAILURE CODE (#R26B3) 530
FAILURE CODE (#R26B4) 531
FAILURE CODE (#R26B5) 532
FAILURE CODE (#R26BB) 533
FAILURE CODE (#R26OB) 534
FAILURE CODE (#R26P3) 535
FAILURE CODE (#R26P4) 536
FAILURE CODE (#R26P5) 537
FAILURE CODE (#R26PB) 538
FAILURE CODE (#R280B) 539
FAILURE CODE (#R2813) 540
FAILURE CODE (#R2814) 541
FAILURE CODE (#R2815) 542
FAILURE CODE (#R281B) 543
FAILURE CODE (#R2BKB) 544
FAILURE CODE (#R2BLB) 545
FAILURE CODE (#R2J92) 546
FAILURE CODE (#R2J9V) 547
FAILURE CODE (#R2JK2) 548
FAILURE CODE (#R2JK9) 549
FAILURE CODE (#R2JKB) 550
FAILURE CODE (#R2JL2) 551
FAILURE CODE (#R2JL9) 552
FAILURE CODE (#R2JLB) 553
FAILURE CODE (#R2JM2) 554
FAILURE CODE (#R2JM9) 555
FAILURE CODE (#R2JMB) 556
FAILURE CODE (#R2JN2) 557
FAILURE CODE (#R2JN9) 558
FAILURE CODE (#R2JNB) 559
FAILURE CODE (#R2JO2) 560
FAILURE CODE (#R2JO9) 561
FAILURE CODE (#R2JOB) 562
FAILURE CODE (#R2JP2) 563
FAILURE CODE (#R2JP9) 564
FAILURE CODE (#R2JPB) 565
FAILURE CODE (#R2JR2) 566
FAILURE CODE (#R2JR9) 567
FAILURE CODE (#R2JRB) 568
FAILURE CODE (#R2JS2) 569
FAILURE CODE (#R2JS9) 570
FAILURE CODE (#R2JSB) 571
FAILURE CODE (#R2JT2) 572
FAILURE CODE (#R2JT9) 573
FAILURE CODE (#R2JTB) 574
FAILURE CODE (#R2JU2) 575
FAILURE CODE (#R2JU9) 576
FAILURE CODE (#R2JUB) 577
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E- MODE) . 578
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 597
TROUBLESHOOTING OF ENGINE (S-MODE) . 606
S-4 ENGINE STARTABILITY IS POOR 610
S-9 EXHAUST SMOKE IS BLACK . 618
S-12 FUEL CONSUMPTION IS EXCESSIVE . 622
S-14 OIL PRESSURE DROPS 624
S-18 UNUSUAL NOISE IS HEARD 628
S-19 VIBRATION IS EXCESSIVE 629
DISASSEMBLY AND ASSEMBLY . 633
ABBREVIATION LIST 635
List of abbreviations used in the text . 635
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 640
HOW TO READ THIS MANUAL 640
Reading the work procedures 640
Reading the symbols 640
Reading the signal word 641
Reading the unit . 641
COATING MATERIALS LIST . 642
Adhesive . 642
Liquid gasket 643
Molybdenum disulfide lubricant . 643
Seizure prevention compound 644
Grease . 644
Primer . 645
Adhesive . 645
Caulking material 645
ENGINE AND COOLING SYSTEM 646
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 646
Removal of supply pump assembly 646
Reassembly of supply pump 648
REMOVE AND INSTALL INJECTOR ASSEMBLY . 650
Removal of injector 650
Reassembly of injector . 651
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 653
Remove cylinder head assembly 654
Install the cylinder head 657
REMOVE AND INSTALL EGR VALVE ASSEMBLY 663
Remove the EGR cooler assembly . 663
Remove the EGR valve . 664
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY . 665
Removal of Starter Motor . 665
Disassembly of Starter Motor . 665
Reassembly of Starter Motor 668
Install the Starter Motor 669
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT . 670
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT 670
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT 671
REMOVE AND INSTALL ALTERNATOR BELT . 672
REMOVE AND INSTALL ALTERNATOR ASSEMBLY . 674
Remove the alternator assembly . 674
Install alternator assembly 675
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 676
Removal of fan assembly 676
Installation of fan assembly . 677
REMOVE AND INSTALL RADIATOR AND HYDRAULIC TANK ASSEMBLY 677
Removal of radiator and hydraulic tank assembly 677
Installation of radiator and hydraulic tank assembly . 680
REMOVE AND INSTALL ENGINE ASSEMBLY . 681
Remove engine assembly . 681
INSTALLATION OF ENGINE ASSEMBLY 685
REMOVE AND INSTALL ENGINE FRONT OIL SEAL . 686
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 687
Removal of engine hood assembly consisting of plastic and steel hood . 687
Removal of steel hood 687
Installation of steel hood . 688
Removal of engine hood assembly 688
Installation of engine hood assembly . 689
REMOVE AND INSTALL AFTERTREATMENT DEVICE . 690
METHOD FOR REMOVING AFTER TREATMENT DEVICE ASSEMBLY 691
REMOVE AND INSTALL FUEL TANK ASSEMBLY 693
Remove the fuel tank . 693
Installation of fuel tank 694
Fuelling fuel tank . 694
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 695
Removal of air cleaner assembly 695
Installation of air cleaner assembly . 696
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY . 696
Removal of air conditioner compressor assembly . 697
Installation of air compressor assembly 697
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 698
Remove air conditioner condenser assembly 699
Installation of air conditioner condenser assembly . 700
POWER TRAIN 702
PUMP FOR STEERING, WORK EQUIPMENT, COOLING FAN . 702
Removal of the pump for steering, work equipment and cooling fan . 702
Installation of hydraulic pump assembly 702
ARTICULATED JOINT ASSEMBLY . 703
Removal of articulation joint assembly . 703
Installation of articulation joint assembly 703
HST MOTOR ASSEMBLY . 704
Removal of HST motor assembly 704
Installation of variable motor assembly 705
HST PUMP ASSEMBLY 706
Removal of HST pump assembly . 706
Installation of variable motor assembly 707
GEARBOX (TRANSFER ASSEMBLY) 708
PRECAUTIONS FOR ASSEMBLY AND DISASSEMBLY . 708
Safety precautions . 708
HYDRAULIC GEAR CONTROL . 709
Exploded view 709
Disassembly 710
Assembly . 713
HYDRAULIC GEAR CONTROL (CONTACTLESS SENSOR) 718
Exploded view 718
Disassembly 719
Assembly . 723
COUNTER-REVOLUTION SENSOR 729
Replacement 729
SHORT FLANGED REDUCTION GEAR . 730
Exploded view 730
Disassembly 731
Assembly . 739
GEARBOX INSTALLATION . 752
Disassembly 752
INTEGRATED GEAR BOX 755
Disassembly 756
Assembly . 760
Special Tool . 764
REAR AXLE ASSEMBLY . 765
Removal of rear axle assembly 765
Installation of rear axle assembly . 767
PRECAUTIONS FOR ASSEMBLY AND DISASSEMBLY OF AXLE COMPONENTS 768
Safety precautions . 768
PLANETARY REDUCTION AND AXLE SHAFT . 769
Exploded view 769
Disassembly 770
Assembly . 774
Special Tools 778
RING AND PINION ADJUSTING: STEP FOR PRELOADED DIFFERENTIAL . 780
Exploded view 780
Install and adjust . 781
DIFFERENTIAL WITH BLOCK TO SPHERES 100% 784
Exploded view 784
Disassembly 785
Assembly . 788
LIMITED SLIP DIFFERENTIAL UNIT 45% . 791
Exploded view 791
Disassembly 792
Assembly . 794
FRONT AXLE ASSEMBLY 797
Removal of front axle assembly . 797
Installation of front axle assembly 798
PRECAUTIONS FOR ASSEMBLY AND DISASSEMBLY OF AXLE COMPONENTS 799
Safety precautions . 799
CHECKING WEAR AND REPLACING THE BRAKING DISCS 800
Exploded view 800
Disassembly 801
Assembly . 803
Special tools 805
DISASSEMBLY AND ASSEMBLY AXLE HOUSING ASSEMBLY . 806
PLANETARY REDUCTION AND AXLE SHAFT . 806
Exploded view 806
Disassembly 807
Assembly . 811
Special tools 815
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ASSEMBLY . 818
Differential unit 818
Exploded view 818
Disassembly 819
Assembly . 821
Special tools 823
MANUAL EMERGENCY RELEASE . 824
Exploded view 824
Release 825
Adjustment . 826
MECHANICAL PARKING BRAKE . 827
Exploded view 827
Disassembly 828
Assembly . 830
NORMAL DIFFERENTIAL UNIT . 832
Exploded view 832
Disassembly 833
Assembly . 835
Special tools 838
LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%) . 841
Exploded view 841
Disassembly 842
Assembly . 845
Special tools 848
HYDRAULIC DIFFERENTIAL LOCK 851
Exploded view 851
Disassembly 852
Assembly . 855
Special tools 857
UNDERCARRIAGE AND FRAME 858
REMOVAL AND INSTALLATION OF COUNTERWEIGHTASSEMBLY 858
Removal of counterweight assembly 858
Installation of counterweight assembly . 858
HYDRAULIC SYSTEM . 859
REMOVE AND INSTALL LIFT CYLINDER ASSEMBLY 859
Remove lift cylinder assembly 859
Removal of lift cylinder assembly 859
Install lift cylinder assembly . 860
REMOVE AND INSTALL DUMP CYLINDER ASSEMBLY 860
Remove dumb cylinder assembly 860
Remove dump cylinder assembly 860
Installation of dump cylinder assembly . 861
REMOVE AND INSTALL STEERING CYLINDER ASSEMBLY 861
Remove steering cylinder assembly 862
Remove steering cylinder assembly 862
Install steering cylinder assembly . 862
WORK EQUIPMENT SYSTEM 863
REMOVE AND INSTALL MAIN VALVE ASSEMBLY . 863
Removal of main control valve assembly . 863
Installation of main control valve assembly 866
Removal of multifunction lever . 867
REMOVE AND INSTALL QUICK COUPLER ASSEMBLY 868
Remove quick coupler assembly 868
Install quick coupler assembly . 869
CAB AND ITS ATTACHMENTS 870
REMOVE AND INSTALL OPERATOR‘S CAB GLASS (ADHERED GLASS) 870
Preparation work for replacing the front window pane . 871
Preparation work for replacing the rear window pane 871
Preparation work for replacing the door window pane 872
Left door assembly . 872
Right door assembly 872
Remove operator’s cab glass (adhered glass) 872
Install operator’s cab glass (adhered glass) . 874
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY . 876
Remove air conditioner unit assembly . 877
Install heater unit assembly . 879
REMOVE AND INSTALL OPERATOR‘S SEAT ASSEMBLY 879
Remove operator‘s seat assembly (STD) 879
Install operator‘s seat assembly (STD) . 880
Remove operator‘s seat assembly (air suspension, heatable) . 880
Install operator‘s seat assembly (air suspension, heatable) 881
REMOVE AND INSTALL SEAT BELT . 882
Remove seat belt on STD seat . 882
Install seat belt on STD seat 883
Remove seat belt on suspension, heatable seat 883
Install seat belt on suspension, heatable seat . 884
ELECTRICAL SYSTEM 885
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 885
Method for removing engine controller assembly . 886
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY . 888
Method for removing the cover of the console . 888
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 889
Method for removing machine monitor assembly . 889
Method for installing machine monitor assembly . 892
REMOVE AND INSTALL CENTRAL ELECTRIC BOARD (CEB) 893
Remove the cover of the console 893
Remove central electric board (CEB) 894
Remove I/O controller 64P 894
Remove differential lock relay . 894
Install differential lock rely . 894
Install I/O controller 64P . 895
Install central electric boar (CEB) 895
Installation of the cover of the console . 896
REMOVE AND INSTALL RELAYBOX 898
Remove relaybox 898
Remove battery relay . 899
Remove the grommet frame from cables . 899
Install the battery relay 900
Install the grommet frame to cables 900
Install relay box 901
REMOVE AND INSTALL EPC CONTROLLER ASSEMBLY . 902
Method for removing the cover of the console . 902
MAINTENANCE STANDARD . 903
ABBREVIATION LIST 905
List of abbreviations used in the text . 905
List of abbreviations used in the circuit diagrams . 910
ENGINE AND COOLING . 911
MAINTENANCE STANDARD OF ENGINE MOUNT . 911
MAINTENANCE STANDARD OF DAMPER . 912
MAINTENANCE STANDARD OF COOLING FAN MOTOR 913
HYDRAULIC SYSTEM . 914
CAB AND ITS ATTACHMENTS 918
Cabin – adjustment . 918
APPENDIX . 919
ABBREVIATION LIST 921
List of abbreviations used in the text . 921
List of abbreviations used in the circuit diagrams . 926
AIR CONDITIONER SYSTEM . 927
PRECAUTIONS FOR REFRIGERANT 927
AIR CONDITIONER COMPONENT 928
Specifications of air conditioner 928
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 929
OUTLINE OF REFRIGERATION CYCLE . 930
Compression (Compressor) . 930
Condensation (Condenser) . 930
Expansion (Expansion valve) 930
Evaporation (Evaporator) . 931
Relation between refrigerant and cooling trouble . 931
AIR CONDITIONER TROUBLESHOOTING CHART 933
Cooling trouble 933
Heating trouble 933
CONNECTION OF SERVICE TOOL . 934
METHOD FOR CONNECTING SERVICE TOOL . 935
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 936
Precautions for disconnection 936
Precautions for connection . 937
HANDLE COMPRESSOR OIL 938
Management of compressor oil (SANDEN: SP-10 for use with R134a) 938
Filling of compressor oil 938
The quantity of compressor oil when the compressor is replaced . 939
OTHER 941
HYDRAULIC CIRCUIT DIAGRAM 945
WIRING DIAGRAMS 948
Contents . 948
1-0 SYMBOLS SUMMARY, ABBREVIATIONS . 949
1-1 HARNESS ARRANGEMENT DETAILS, JOYSTICK BUTTONS 950
1-2 CAN BUS SUMMARY 951
2-0 POWER SUPPLY, STARTER SWITCH . 952
2-1 GROUNDING 953
2-2 RELAYB., STARTER, ALTERN., BATTERY, GLOW PLUG 954
2-3 MAIN ENGINE (EGR) RELAYS . 955
3-0 AFTERTREATMENT SYS., DPF SENS., OIL PRESS., TRAVEL PED . 956
3-1 ECU, ENGINE SENSORS 957
3-2 INJECTOR, FUEL PUMP, AIR CLEANER, WATER SEPA . 958
4-0 MONITOR, I/O CONTROLLER 64P, BUZZER 959
4-1 KOMTRAX CTRL, SERVICE CONNECTOR 960
4-2 FLUID-SENSORS (OIL, FUEL, COOLANT), SPEED SENS . 961
5-0 SEC. ENG. STOP, IMMOBILIZER, DRIVING FUNCT . 962
5-1 HST CONTROLLER . 963
5-2 HST CONTROLLER INPUTS 964
5-3 CREEP 965
6-0 FAN DRIVE, REVERSE FAN . 966
7-0 AIR CONDITIONER, OPERATOR’S SEATI 967
7-1 WASHER, WIPER, REAR WINDOW HEATER, HORN 968
8-0 LIGHTING FRONT . 969
8-1 FLASHER 970
8-2 REAR LIGHT, LICENSE PL., BACKUP AL., REAR FLASH 971
8-3 WORK LAMPS . 972
8-4 INTERIOR LAMP, ROTATING BEACON, PLUG BOX . 973
9-0 3RD HYDRAULIC CIRCUIT EPC INPUT 974
9-1 3RD HYDRAULIC CIRCUIT EPC OUTPUT . 975
10-0 DRIVING RANGE, ECSS, OVER CENTER V., AUTO INCH 976
10-1 RETURN TO DIG, QUICK COUPLER, DIFF LOCK . 977
10-2 RADIO, BLANK OPT., DPF REGEN. SW, MAINT. SW . 978
10-3 CREEP SC DA . 979
W1 WIRING HARNESS LIST . 980
W2 CONNECTOR LIST 1 981
W2 CONNECTOR LIST 2 982
W2 CONNECTOR LIST 3 983
W2 CONNECTOR LIST 4 984
W2 CONNECTOR LIST 5 985
W2 CONNECTOR LIST 6 986
W3 PIN LOCATION LIST 1 . 987
W3 PIN LOCATION LIST 2 . 988
W3 PIN LOCATION LIST 3 . 989
W3 PIN LOCATION LIST 4 . 990
W3 PIN LOCATION LIST 5 . 991
W3 PIN LOCATION LIST 6 . 992
W3 PIN LOCATION LIST 7 . 993
W3 PIN LOCATION LIST 8 . 994
W3 PIN LOCATION LIST 9 . 995
W3 PIN LOCATION LIST 10 996
W3 PIN LOCATION LIST 11 997
W3 PIN LOCATION LIST 12 998
W3 PIN LOCATION LIST 13 999
W3 PIN LOCATION LIST 14 1000
W3 PIN LOCATION LIST 15 1001
W3 PIN LOCATION LIST 16 1002
W3 PIN LOCATION LIST 17 1003
W3 PIN LOCATION LIST 18 1004
W3 PIN LOCATION LIST 19 1005
W3 PIN LOCATION LIST 20 1006
W3 PIN LOCATION LIST 21 1007
W3 PIN LOCATION LIST 22 1008
W3 PIN LOCATION LIST 23 1009
W3 PIN LOCATION LIST 24 1010
W3 PIN LOCATION LIST 25 1011
W3 PIN LOCATION LIST 26 1012
W3 PIN LOCATION LIST 27 1013
W3 PIN LOCATION LIST 28 1014
W3 PIN LOCATION LIST 29 1015
W3 PIN LOCATION LIST 30 1016
W3 PIN LOCATION LIST 31 1017
W3 PIN LOCATION LIST 32 1018
W3 PIN LOCATION LIST 33 1019
W3 PIN LOCATION LIST 34 1020
W4 PARTS LIST 1 1021
W4 PARTS LIST 2 1022
W4 PARTS LIST 3 1023
Connector diagram 1 1024
Connector diagram 2 1025
Connector diagram 3 1026
Connector table for the operator‘s cab wiring harness (Part 1/2) .1026
Connector diagram 4 1027
Connector table for operator‘s cab wiring harness (Part 2/2) .1027
Connector diagram 5 1028

DESCRIPTION:

Komatsu WA80M-8E0 Wheel Loader Shop Manual VENBM08003  – PDF DOWNLOAD

• Model               Serial number
  WA80M-8E0   H81431 and up

G.B 27/12/24