Komatsu WA180-3 Parallel Tool Carrier Shop Manual CEBM001900

Description

• Model List:
  • WA180-3 Parallel Tool Carrier

• 1. MAIN MENU
• 2. CONTENTS
• 3. GENERAL
• 3.1. SPECIFICATION DRAWINGS
• 3.2. SPECIFICATIONS
• 3.3. WEIGHT TABLE
• 3.4. FUEL, COOLANT AND LUBRICANTS
• 3.5. ENGINE OIL SPECIFICATIONS
• 3.6. DIESEL FUEL SPECIFICATIONS
• 3.7. COOLANT SPECIFICATIONS
• 4. STRUCTURE AND FUNCTION
• 4.1. POWER TRAIN
• 4.2. PATH OF POWER TRANSMISSION
• 4.3. TORQUE CONVERTER TRANSMISSION PIPING
• 4.4. TORQUE CONV., TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
• 4.5. TORQUE CONV., TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
• 4.6. TORQUE CONVERTER
• 4.7. TORQUE CONVERTER OIL FILTER
• 4.8. TRANSMISSION
• 4.9. TRANSMISSION CONTROL VALVE
• 4.10. TRANSMISSION CONTROL
• 4.11. DRIVE SHAFT
• 4.12. AXLE
• 4.13. FINAL DRIVE
• 4.14. AXLE MOUNT
• 4.15. CENTER HINGE PIN
• 4.16. STEERING PIPING
• 4.17. STEERING COLUMN
• 4.18. PRIORITY VALVE
• 4.19. CUSHION VALVE
• 4.20. STEERING VALVE (ORBITROLL)
• 4.21. STEERING VALVE
• 4.22. BRAKE PIPING
• 4.23. BRAKE CONTROL
• 4.24. BRAKE BOOSTER
• 4.25. PARKING BRAKE CONTROL
• 4.26. PARKING BRAKE
• 4.27. HYDRAULIC PIPING
• 4.28. STEERING, HYDRAULIC PUMP HYDRAULIC SYSTEM DIAGRAM
• 4.29. STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
• 4.30. HYDRAULIC TANK
• 4.31. MAIN CONTROL VALVE
• 4.32. PILOT SOLENOID VALVE
• 4.33. WORK EQUIPMENT LEVER LINKAGE
• 4.34. BUCKET
• 4.35. BUCKET POSITIONER AND BOOM KICKOUT
• 4.36. ROPS CAB
• 4.37. AIR CONDITIONER/HEATER PIPING
• 4.38. AIR CONDITIONER ELECTRIC CIRCUIT DIAGRAM (EAGLE)
• 4.39. ELECTRICAL WIRING ILLUSTRATION
• 4.40. ELECTRICAL WIRING DIAGRAM (1/3)
• 4.41. ELECTRICAL WIRING DIAGRAM (2/3)
• 4.42. ELECTRICAL WIRING DIAGRAM (3/3)
• 4.43. CENTRAL PANEL (CLUSTER GUAGE)
• 4.44. SENSOR
• 4.45. ENGINE STARTING CIRCUIT
• 4.46. ENGINE STOP CIRCUIT
• 4.47. AUTOMATIC PREHEATING CIRCUIT (Q.H.S. CIRCUIT)
• 4.48. ELECTRICAL TRANSMISSION CONTROL
• 4.49. COMBINATION SWITCH
• 4.50. TRANSMISSION CUTOFF FUNCTION
• 4.51. PARKING BRAKE FUNCTION
• 4.52. KICK DOWN SWITCH
• 4.53. KICK DOWN ELECTRIC CIRCUIT DIAGRAM
• 4.54. DUMP SPEED SWITCH
• 4.55. QUICK COUPLER SWITCH
• 5. TESTING AND ADJUSTING
• 5.1. STANDARD VALUE TABLE FOR ENGINE
• 5.2. STANDARD VALUE TABLE FOR CHASSIS
• 5.3. TOOLS FOR TESTING, ADJUSTING TROUBLESHOOTING
• 5.4. MEASURING ENGINE SPEEDS
• 5.5. MEASURING ENGINE LUBRICATING OIL PRESSURE
• 5.6. MEASURING FUEL FILTER INLET RESTRICTION
• 5.7. MEASURING BLOWBY PRESSURE
• 5.8. MEASURING COMPRESSION PRESSURE
• 5.9. MEASURING EXHAUST COLOR
• 5.10. MEASURING COOLANT TEMPERATURE
• 5.11. MEASURING AND ADJUSTING VALVE CLEARANCE
• 5.12. MEASURING ACCELERATOR PEDAL
• 5.13. MEASURING OPERATING FORCE TRAVEL OF SPEED LEVER
• 5.14. MEASURING STALL SPEEDS
• 5.15. MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE
• 5.16. METHOD OF OPERATING EMERGENCY MANUAL SPOOL
• 5.17. TESTING AND ADJUSTING STEERING WHEEL
• 5.18. MEASURING STEERING OIL PRESSURE
• 5.19. MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL
• 5.20. TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
• 5.21. MEASURING BRAKE PERFORMANCE
• 5.22. MEASURING BRAKE OIL PRESSURE
• 5.23. MEASURING BRAKE DISC WEAR
• 5.24. BLEEDING AIR FROM BRAKE SYSTEM
• 5.25. MEASURING PARKING BRAKE PERFORMANCE
• 5.26. TESTING AND ADJUSTING PARKING BRAKE LINKAGE
• 5.27. TESTING PARKING BRAKE DISC WEAR
• 5.28. MEASURING PARKING BRAKE DISC WEAR
• 5.29. MEASURING WORK EQUIPMENT CONTROL LEVER
• 5.30. MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL
• 5.31. MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
• 5.32. MEASURING WORK EQUIPMENT CYCLE TIMES
• 5.33. MEASURING WORK EQUIPMENT HYDRAULIC DRIFT
• 5.34. TESTING AND ADJUSTING BOOM KICKOUT (IF EQUIPPED)
• 5.35. TESTING AND ADJUSTING BUCKET / FORK POSITIONER
• 5.36. ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)
• 5.37. CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR
• 5.38. TROUBLESHOOTING TABLE OF CONTENTS
• 5.38.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.38.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 5.38.3. PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
• 5.38.4. CHECKS BEFORE TROUBLESHOOTING
• 5.38.5. HANDLING CONNECTORS
• 5.38.6. PRECAUTIONS WHEN TROUBLESHOOTING
• 5.38.7. PREVENTING RECURRENCE OF TROUBLE
• 5.38.8. METHOD OF USING TROUBLESHOOTING CHARTS
• 5.38.9. TROUBLESHOOTING OF ENGINE SYSTEM TABLE OF CONTENTS
• 5.38.9.1. S1 STARTING PERFORMANCE IS POOR (Starting always takes time)
• 5.38.9.2. S2 Engine does not start
• 5.38.9.3. S3 Engine does not pick up smoothly (Follow up is poor)
• 5.38.9.4. S4 Engine stops during operations
• 5.38.9.5. S5 Engine does not rotate smoothly (hunting)
• 5.38.9.6. S6 Engine lacks output (no power)
• 5.38.9.7. S7 Exhaust gas is black (incomplete combustion)
• 5.38.9.8. S8 Oil consumption is excessive (or exhaust gas is blue)
• 5.38.9.9. S9 Oil becomes contaminated quickly
• 5.38.9.10. S10 Fuel consumption is excessive
• 5.38.9.11. S11 Oil is in cooling water, or water spurts back, or water level goes down
• 5.38.9.12. S12 Oil pressure lamp lights up (drop in oil pressure)
• 5.38.9.13. S13 Oil level rises
• 5.38.9.14. S14 Water temperature becomes too high (overheating)
• 5.38.9.15. S15 Abnormal noise is made
• 5.38.9.16. S16 Vibration is excessive
• 5.38.10. TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) TABLE OF CONTENTS
• 5.38.10.1. POWER TRAIN
• 5.38.10.2. STEERING SYSTEM
• 5.38.10.3. BRAKE SYSTEM
• 5.38.10.4. WORK EQUIPMENT
• 5.38.11. TROUBLESHOOTINGEAGLE AIR CONDITIONER
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. METHOD OF USING MANUAL
• 6.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 6.3. SPECIAL TOOL LIST
• 6.4. STARTING MOTOR
• 6.4.1. REMOVAL AND INSTALLATION
• 6.5. ALTERNATOR
• 6.5.1. REMOVAL AND INSTALLATION
• 6.6. FUEL INJECTION PUMP
• 6.6.1. REMOVAL
• 6.6.2. INSTALLATION
• 6.7. ENGINE OIL COOLER
• 6.7.1. REMOVAL AND INSTALLATION
• 6.8. WATER PUMP
• 6.8.1. REMOVAL AND INSTALLATION
• 6.9. NOZZLE HOLDER
• 6.9.1. REMOVAL AND INSTALLATION
• 6.10. THERMOSTAT
• 6.10.1. REMOVAL AND INSTALLATION
• 6.11. TURBOCHARGER
• 6.11.1. REMOVAL AND INSTALLATION
• 6.12. CYLINDER HEAD
• 6.12.1. REMOVAL AND INSTALLATION
• 6.13. EXHAUST MUFFLER
• 6.14. TORQUE CONVERTER CHARGING PUMP
• 6.14.1. REMOVAL AND INSTALLATION
• 6.15. TORQUE CONVERTER, TRANSMISSION
• 6.15.1. REMOVAL
• 6.15.2. INSTALLATION
• 6.16. TORQUE CONVERTER
• 6.17. TRANSMISSION CLUTCH PACK
• 6.17.1. DISASSEMBLY
• 6.17.2. ASSEMBLY
• 6.18. TRANSMISSION CONTROL VALVE
• 6.18.1. REMOVAL
• 6.18.2. INSTALLATION
• 6.18.3. DISASSEMBLY
• 6.18.4. ASSEMBLY
• 6.19. TRANSMISSION SOLENOID VALVE
• 6.19.1. DISASSEMBLY AND ASSEMBLY
• 6.20. TRANSMISSION ACCUMULATOR VALVE
• 6.21. CENTER HINGE PIN
• 6.21.1. REMOVAL
• 6.21.2. INSTALLATION
• 6.22. PILOT SOLENOID VALVE
• 6.23. MAIN CONTROL VALVE
• 6.23.1. REMOVAL
• 6.23.2. INSTALLATION
• 6.23.3. DISASSEMBLY
• 6.23.4. ASSEMBLY
• 6.24. STEERING CYLINDER
• 6.25. HYDRAULIC FILTER
• 6.25.1. REMOVAL AND INSTALLATION
• 6.26. HYDRAULIC STEERING PUMP
• 6.27. HYDRAULIC CYLINDER
• 6.27.1. DISASSEMBLY
• 6.27.2. ASSEMBLY
• 6.28. BOOM AND PARALLEL TOOL LINKAGE
• 6.28.1. REMOVAL AND INSTALLATION
• 6.29. INSTRUMENT PANEL
• 6.29.1. REMOVAL AND INSTALLATION
• 7. MAINTENANCE STANDARD
• 7.1. ENGINE MOUNT, TRANSMISSIONMOUNT
• 7.2. TORQUE CONVERTER CHARGING PUMP
• 7.3. TORQUE CONVERTER
• 7.4. TRANSMISSION
• 7.5. TRANSMISSION CONTROL VALVE
• 7.6. ACCUMULATOR VALVE
• 7.7. DRIVE SHAFT
• 7.8. DIFFERENTIAL
• 7.9. FINAL DRIVE
• 7.10. AXLE MOUNT
• 7.11. CENTER HINGE PIN
• 7.12. STEERING COLUMN
• 7.13. STEERING CYLINDER MOUNT
• 7.14. MAIN CONTROL VALVE
• 7.14.1. SPOOL VALVE
• 7.14.2. SPOOL VALVE
• 7.15. PILOT SOLENOID VALVE
• 7.16. HYDRAULIC CYLINDER
• 7.17. WORK EQUIPMENT LINKAGE
• 7.18. BUCKET POSITIONER AND BOOM KICKOUT
• 7.19. ADDITIONAL COUNTERWEIGHT