Komatsu WA80M-8E0 Wheel Loader Shop Manual VENBM08000 PDF

Description

Komatsu WA80M-8E0 Wheel Loader Shop Manual VENBM08000 –  PDF DOWNLOAD

FILE DETAILS:

Komatsu WA80M-8E0 Wheel Loader Shop Manual VENBM08000 –  PDF DOWNLOAD

Language : English
Pages : 853
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA80M-8E0 Wheel Loader Shop Manual VENBM08000 –  PDF DOWNLOAD

• WA80M-8E0     H81051 and up

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 . 93
ABBREVIATION LIST 97
List of abbreviations used in the text . 97
List of abbreviations used in the circuit diagrams .102
ELECTRICAL SYSTEM 103
BOOT-UP SYSTEM .104
LAYOUT DRAWING OF BOOT-UP SYSTEM .104
AROUND THE CAB AND FLOOR .105
BATTERY DISCONNECT SWITCH 106
FUNCTION OF BATTERY DISCONNECT SWITCH 106
PREHEATING SYSTEM 108
FUNCTION OF AUTOMATIC PREHEATING SYSTEM 109
OPERATION OF AUTOMATIC PREHEATING SYSTEM .109
ENGINE SYSTEM 110
LAYOUT DRAWING OF ENGINE SYSTEM 110
COOLING SYSTEM .111
LAYOUT DRAWING OF COOLING SYSTEM .111
SPECIFICATIONS OF COOLING SYSTEM .112
COOLING FAN CONTROL SYSTEM .113
FUNCTION OF COOLING FAN CONTROL SYSTEM .114
COOLING FAN REVERSE ROTATION FUNCTION (Option) .114
COMPONENT PARTS OF COOLING SYSTEM 115
STRUCTURE OF COOLING FAN MOTOR .115
CONTROL SYSTEM .116
AROUND THE CAB AND FLOOR .117
MACHINE MONITOR SYSTEM .118
MACHINE MONITOR SYSTEM DIAGRAM .118
KOMTRAX SYSTEM .119
KOMTRAX SYSTEM DIAGRAM .119
FUNCTION OF KOMTRAX SYSTEM .119
COMPONENT PARTS OF CONTROL SYSTEM 120
MACHINE MONITOR 120
Function of KOMTRAX terminal .130
HST CONTROLLER .132
Structure of HST controller 132
Real time monitoring function 132
Self-diagnosis function 132
CAN TERMINATING RESISTOR .133
Function of CAN terminating resistor .133
ENGINE CONTROLLER 134
Real time monitoring function 134
Self-diagnosis function 134
ACCELERATOR PEDAL 135
Acceleration signal 135
Idling validation signal .135
Output Characteristics .136
HYDRAULIC SYSTEM .137
Structure of hydraulic tank 138
Specifications of hydraulic tank .138
Structure of main control valve 140
POWER TRAIN SYSTEM .142
OPERATION OF POWER TRAIN SYSTEM 143
FUNCTION OF THE CLOSED CIRCUIT SYSTEM 145
SPECIFICATIONS OF THE HST SYSTEM .145
STRUCTURE OF THE HST SYSTEM 146
20km/h without SpeedControl 146
20km/h or 40km/h with SpeedControl .147
COMPONENT PARTS OF POWER TRAIN SYSTEM 148
Structure of drive shaft .148
Function of drive shaft 148
Structure of HST pump 149
Operation of HST pump 151
Components of HST pump .152
HST motor 156
Structure of transfer box 158
Function of transfer box .159
Structure of front axle 160
Structure of rear axle .161
Function of differential .163
Function of towing system 165
WORK EQUIPMENT SYSTEM 166
Layout of work equipment system 166
WORK EQUIPMENT LOCK SYSTEM .168
ECSS (Option) 169
Function of ECSS .169
Operation of ECSS 169
RETURN TO DIG (option) .170
Structure 170
Function .170
Main control valve .171
Emergency lowering .171
Loader Linkage with quick-coupler 173
STEERING SYSTEM 175
STEERING COLUMN 176
Structure of steering column .176
General view .176
PRIORITY VALVE .179
ORBITROL-VALVE .180
STEERING RELIEF VALVE 181
BRAKE SYSTEM .182
LAYOUT DRAWING OF BRAKE SYSTEM .182
SERVICE BRAKE ASSEMBLY .183
Inching Function .183
PARKING BRAKE ASSEMBLY .185
STRUCTURE OF BRAKE SYSTEM 185
UNDERCARRIAGE AND FRAME 186
Rear axle mount 187
Frame, axle mount and center hinge pin .188
TIRE .189
Structure of radial tire .189
General view .189
Structure 189
Structure of bias tire .190
General view .190
Structure 190
WORK EQUIPMENT .191
STRUCTURE OF WORK EQUIPMENT 191
STRUCTURE OF BUCKET 192
General view and sectional view 192
CAB AND ITS ATTACHMENTS 193
ROPS FOPS CAB 193
Structure of ROPS FOPS cab .193
Function of ROPS FOPS cab 194
CAB MOUNT 195
Structure of cab mount .195
General view .195
Function of cab mount 195
STANDARD VALUE TABLE .207
ABBREVIATION LIST 208
List of abbreviations used in the text .208
List of abbreviations used in the circuit diagrams .213
STANDARD VALUE TABLE .214
Standard value table for engine 214
Standard value table for chassis .215
TEST CERTIFICATE .217
TESTING AND ADJUSTING 219
ABBREVIATION LIST 223
List of abbreviations used in the text .223
List of abbreviations used in the circuit diagrams .229
TEST ENGINE WITH SOFTWARE TOOL .230
CONNECTION OF A COMPUTER TO THE MACHINE 230
ENGINE AND COOLING SYSTEM 232
TEST ENGINE SPEED 232
Method for testing engine speed 232
Method for testing engine low idle speed .232
Method for testing engine high idle speed 233
Method for testing engine speed HST stall 234
Method for testing engine speed at hydraulic stall .235
Method for testing engine speed at full stall (HST stall and hydraulic stall) 236
TEST EXHAUST GAS COLOUR 238
Testing tool for exhaust gas colour 238
TEST AND ADJUST VALVE CLEARANCE 240
METHOD FOR TESTING AND ADJUSTINGVALVE CLEARANCE 241
TEST COMPRESSION PRESSURE 242
METHOD FOR TESTING COMPRESSION PRESSURE 242
Compression pressure inspection procedures .243
Injector reassembly procedures .244
TEST ENGINE OIL PRESSURE .245
METHOD FOR TESTING ENGINE OIL PRESSURE .245
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM .246
TEST FUEL CIRCUIT FOR LEAKAGE 247
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 247
Testing method of fuel circuit for leakage at engine stopped .247
Testing method of fuel circuit for leakage at engine low idle 248
Testing method of fuel circuit for leakage at engine high idle .248
HANDLE NO-INJECTION CRANKING OPERATION .249
TEST DOC AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 250
METHOD FOR TESTING DOC AND MUFFLER STACK FOR LOOSENESS AND DAMAGE 250
TEST INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS .251
METHOD FOR TESTING INSTALLED CONDITION OF CYLINDER HEADS AND MANIFOLDS .251
TEST ENGINE PIPING FOR DAMAGE AND LOOSENESS 252
METHOD FOR TESTING ENGINE PIPING FOR DAMAGE AND LOOSENESS 252
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 253
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 253
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT .254
TEST ALTERNATOR BELT .255
METHOD FOR TESTING ALTERNATOR BELT .255
POWER TRAIN 256
TEST AND ADJUST HST PRESSURE CUT OFF .256
TEST DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE .258
METHOD FOR TESTING DRIVE SHAFT FOR LOOSENESS, BACKLASH, AND DAMAGE .258
STEERING SYSTEM 259
Operating time for steering wheel 259
Operating force of steering wheel 260
TEST AND ADJUST STEERING CIRCUIT OIL PRESSURE 261
METHOD FOR TESTING STEERING CIRCUIT OIL PRESSURE .262
METHOD FOR ADJUSTING STEERING CIRCUIT OIL PRESSURE .263
BLEED AIR FROM STEERING CYLINDER CIRCUIT .264
METHOD FOR BLEEDING AIR FROM STEERING CYLINDER CIRCUIT .264
BLEED AIR FROM BRAKE CIRCUIT .265
TEST BRAKING PERFORMANCE .267
MEASURING THE STOPPING DISTANCE 267
TEST AND ADJUST BRAKE PEDAL 268
TEST WEAR OF WHEEL BRAKE DISC 269
TEST PARKING BRAKE PERFORMANCE .270
HYDRAULIC SYSTEM .271
Release the remaining pressure from small accumulator for gear switching and safety valves (option) 271
Releasing the remaining pressure in ECSS .273
TEST AND ADJUST WORK EQUIPMENT PRESSURE 274
TEST BOOST PRESSURE 275
TESTING AND ADJUSTING COOLING FAN SPEED 276
TEST ECSS ACCUMULATOR NITROGEN GAS PRESSURE 278
METHOD FOR TESTING THE ECSS ACCUMULATOR NITROGEN GAS PRESSURE 279
METHOD FOR CHARGING THE ECSS ACCUMULATOR WITH NITROGEN GAS .280
ELECTRICAL SYSTEM 282
SET AND ADJUST EACH EQUIPMENT 282
SET AND OPERATE MACHINE MONITOR 283
Switch panel .283
Operator mode and service mode of machine monitor 284
OPERATOR MODE 286
Setting usage limitation (password) 286
Change password 287
SERVICE MODE .289
METHOD FOR OPERATING SERVICE MODE 289
Table of self-define monitoring 292
ABNORMALITY RECORD MENU 301
DEFAULT MENU .312
METHOD FOR SETTING WITH DEFAULT SETTING MENU (OPTION SELECTION) 314
ADJUSTMENT MENU 317
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (T/C DEVICE CALIBRATION) .317
HANDLE BATTERY DISCONNECT SWITCH .320
TEST DIODES 322
TROUBLESHOOTING 325
ABBREVIATION LIST 329
List of abbreviations used in the text .329
List of abbreviations used in the circuit diagrams .335
RELATED INFORMATION ON TROUBLESHOOTING .336
GENERAL TROUBLESHOOTING POINTS .336
SEQUENCE OF EVENTS IN TROUBLESHOOTING 338
CHECKS BEFORE TROUBLESHOOTING 340
Engine, lubricating oil and coolant 340
Hydraulic and mechanical equipment .340
Electric equipment .341
Exterior .341
Interior .341
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 342
WALK-AROUND CHECK 342
PROCEDURE FOR TESTING AND TROUBLESHOOTING 344
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE .345
CONNECTOR LOCATION LIST 347
CONNECTOR CONTACT IDENTIFICATION .356
SPARE FUSES AND RELAY 393
USB socket on central electric board (CEB) .398
FAILURE CODES TABLE 401
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 437
TROUBLESHOOTING OF ENGINE (S-MODE) .446
S-4 ENGINE STARTABILITY IS POOR 450
S-9 EXHAUST SMOKE IS BLACK .458
S-12 FUEL CONSUMPTION IS EXCESSIVE .462
S-14 OIL PRESSURE DROPS 464
S-18 UNUSUAL NOISE IS HEARD 468
S-19 VIBRATION IS EXCESSIVE 469
DISASSEMBLY AND ASSEMBLY .471
ABBREVIATION LIST 473
List of abbreviations used in the text .473
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 478
HOW TO READ THIS MANUAL 478
Reading the work procedures 478
Reading the symbols 478
Reading the signal word 479
Reading the unit .479
COATING MATERIALS LIST .480
Adhesive .480
Liquid gasket 481
Molybdenum disulfide lubricant .481
Seizure prevention compound 482
Grease .482
Primer .483
Adhesive .483
Caulking material 483
ENGINE AND COOLING SYSTEM 484
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 484
Removal of supply pump assembly 484
Reassembly of supply pump 486
REMOVE AND INSTALL INJECTOR ASSEMBLY .488
Removal of injector 488
Reassembly of injector .489
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 491
Remove cylinder head assembly 492
Install the cylinder head 495
REMOVE AND INSTALL EGR VALVE ASSEMBLY 501
Remove the EGR cooler assembly .501
Remove the EGR valve .502
REMOVE AND INSTALL STARTING MOTOR ASSEMBLY .503
Removal of Starter Motor .503
Disassembly of Starter Motor .503
Reassembly of Starter Motor 506
Install the Starter Motor 507
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR BELT .508
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR BELT 508
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR BELT 509
REMOVE AND INSTALL ALTERNATOR BELT .510
REMOVE AND INSTALL ALTERNATOR ASSEMBLY .512
Remove the alternator assembly .512
Install alternator assembly 513
REMOVE AND INSTALL COOLING FAN AND FAN MOTOR ASSEMBLY 514
Removal of fan assembly 514
Installation of fan assembly .515
REMOVE AND INSTALL RADIATOR AND HYDRAULIC TANK ASSEMBLY 515
Removal of radiator and hydraulic tank assembly 515
Installation of radiator and hydraulic tank assembly .518
REMOVE AND INSTALL ENGINE ASSEMBLY .519
Remove engine assembly .519
INSTALLATION OF ENGINE ASSEMBLY 523
REMOVE AND INSTALL ENGINE FRONT OIL SEAL .524
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 525
Removal of engine hood assembly consisting of plastic and steel hood .525
Removal of steel hood 525
Installation of steel hood .526
Removal of engine hood assembly 526
Installation of engine hood assembly .527
REMOVE AND INSTALL AFTERTREATMENT DEVICE .528
METHOD FOR REMOVING AFTER TREATMENT DEVICE ASSEMBLY 529
REMOVE AND INSTALL FUEL TANK ASSEMBLY 531
Remove the fuel tank .531
Installation of fuel tank 532
Fuelling fuel tank .532
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 533
Removal of air cleaner assembly 533
Installation of air cleaner assembly .534
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY .534
Removal of air conditioner compressor assembly .535
Installation of air compressor assembly 535
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 536
Remove air conditioner condenser assembly 537
Installation of air conditioner condenser assembly .538
POWER TRAIN 540
PUMP FOR STEERING, WORK EQUIPMENT, COOLING FAN .540
Removal of the pump for steering, work equipment and cooling fan .540
Installation of hydraulic pump assembly 540
ARTICULATED JOINT ASSEMBLY .541
Removal of articulation joint assembly .541
Installation of articulation joint assembly 541
HST MOTOR ASSEMBLY .542
Removal of HST motor assembly 542
Installation of variable motor assembly 543
HST PUMP ASSEMBLY 544
Removal of HST pump assembly .544
Installation of variable motor assembly 545
GEARBOX (TRANSFER ASSEMBLY) 546
PRECAUTIONS FOR ASSEMBLY AND DISASSEMBLY .546
Safety precautions .546
HYDRAULIC GEAR CONTROL .547
Exploded view 547
Disassembly 548
Assembly .551
HYDRAULIC GEAR CONTROL (CONTACTLESS SENSOR) 556
Exploded view 556
Disassembly 557
Assembly .561
COUNTER-REVOLUTION SENSOR 567
Replacement 567
SHORT FLANGED REDUCTION GEAR .568
Exploded view 568
Disassembly 569
Assembly .577
GEARBOX INSTALLATION .590
Disassembly 590
INTEGRATED GEAR BOX 593
Disassembly 594
Assembly .598
Special Tool .602
REAR AXLE ASSEMBLY .603
Removal of rear axle assembly 603
Installation of rear axle assembly .605
PRECAUTIONS FOR ASSEMBLY AND DISASSEMBLY OF AXLE COMPONENTS 606
Safety precautions .606
PLANETARY REDUCTION AND AXLE SHAFT .607
Exploded view 607
Disassembly 608
Assembly .612
Special Tools 616
RING AND PINION ADJUSTING: STEP FOR PRELOADED DIFFERENTIAL .618
Exploded view 618
Install and adjust .619
DIFFERENTIAL WITH BLOCK TO SPHERES 100% 622
Exploded view 622
Disassembly 623
Assembly .626
LIMITED SLIP DIFFERENTIAL UNIT 45% .629
Exploded view 629
Disassembly 630
Assembly .632
FRONT AXLE ASSEMBLY 635
Removal of front axle assembly .635
Installation of front axle assembly 636
PRECAUTIONS FOR ASSEMBLY AND DISASSEMBLY OF AXLE COMPONENTS 637
Safety precautions .637
CHECKING WEAR AND REPLACING THE BRAKING DISCS 638
Exploded view 638
Disassembly 639
Assembly .641
Special tools 643
DISASSEMBLY AND ASSEMBLY AXLE HOUSING ASSEMBLY .644
PLANETARY REDUCTION AND AXLE SHAFT .644
Exploded view 644
Disassembly 645
Assembly .649
Special tools 653
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ASSEMBLY .656
Differential unit 656
Exploded view 656
Disassembly 657
Assembly .659
Special tools 661
MANUAL EMERGENCY RELEASE .662
Exploded view 662
Release 663
Adjustment .664
MECHANICAL PARKING BRAKE .665
Exploded view 665
Disassembly 666
Assembly .668
NORMAL DIFFERENTIAL UNIT .670
Exploded view 670
Disassembly 671
Assembly .673
Special tools 676
LIMITED SLIP DIFFERENTIAL UNIT (25% AND 45%) .679
Exploded view 679
Disassembly 680
Assembly .683
Special tools 686
HYDRAULIC DIFFERENTIAL LOCK 689
Exploded view 689
Disassembly 690
Assembly .693
Special tools 695
UNDERCARRIAGE AND FRAME 696
REMOVAL AND INSTALLATION OF COUNTERWEIGHTASSEMBLY 696
Removal of counterweight assembly 696
Installation of counterweight assembly .696
HYDRAULIC SYSTEM .697
REMOVE AND INSTALL LIFT CYLINDER ASSEMBLY 697
Remove lift cylinder assembly 697
Removal of lift cylinder assembly 697
Install lift cylinder assembly .698
REMOVE AND INSTALL DUMP CYLINDER ASSEMBLY 698
Remove dumb cylinder assembly 698
Remove dump cylinder assembly 698
Installation of dump cylinder assembly .699
REMOVE AND INSTALL STEERING CYLINDER ASSEMBLY 699
Remove steering cylinder assembly 700
Remove steering cylinder assembly 700
Install steering cylinder assembly .700
WORK EQUIPMENT SYSTEM 701
REMOVE AND INSTALL MAIN VALVE ASSEMBLY .701
Removal of main control valve assembly .701
Installation of main control valve assembly 704
Removal of multifunction lever .705
REMOVE AND INSTALL QUICK COUPLER ASSEMBLY 706
Remove quick coupler assembly 706
Install quick coupler assembly .707
CAB AND ITS ATTACHMENTS 708
REMOVE AND INSTALL OPERATOR‘S CAB GLASS (ADHERED GLASS) 708
Preparation work for replacing the front window pane .709
Preparation work for replacing the rear window pane 709
Preparation work for replacing the door window pane 710
Left door assembly .710
Right door assembly 710
Remove operator’s cab glass (adhered glass) 710
Install operator’s cab glass (adhered glass) .712
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .714
Remove air conditioner unit assembly .715
Install heater unit assembly .717
REMOVE AND INSTALL OPERATOR‘S SEAT ASSEMBLY 717
Remove operator‘s seat assembly (STD) 717
Install operator‘s seat assembly (STD) .718
Remove operator‘s seat assembly (air suspension, heatable) .718
Install operator‘s seat assembly (air suspension, heatable) 719
REMOVE AND INSTALL SEAT BELT .720
Remove seat belt on STD seat .720
Install seat belt on STD seat 721
Remove seat belt on suspension, heatable seat 721
Install seat belt on suspension, heatable seat .722
ELECTRICAL SYSTEM 723
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 723
Method for removing engine controller assembly .724
REMOVE AND INSTALL HST CONTROLLER ASSEMBLY .726
Method for removing the cover of the console .726
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 727
Method for removing machine monitor assembly .727
Method for installing machine monitor assembly .730
REMOVE AND INSTALL CENTRAL ELECTRIC BOARD (CEB) 731
Remove the cover of the console 731
Remove central electric board (CEB) 732
Remove I/O controller 64P 732
Remove differential lock relay .732
Install differential lock rely .732
Install I/O controller 64P .733
Install central electric boar (CEB) 733
Installation of the cover of the console .734
REMOVE AND INSTALL RELAYBOX 736
Remove relaybox 736
Remove battery relay .737
Remove the grommet frame from cables .737
Install the battery relay 738
Install the grommet frame to cables 738
Install relay box 739
MAINTENANCE STANDARD .741
ABBREVIATION LIST 743
List of abbreviations used in the text .743
List of abbreviations used in the circuit diagrams .748
ENGINE AND COOLING .749
MAINTENANCE STANDARD OF ENGINE MOUNT .749
MAINTENANCE STANDARD OF DAMPER .750
MAINTENANCE STANDARD OF COOLING FAN MOTOR 751
HYDRAULIC SYSTEM .752
CAB AND ITS ATTACHMENTS 756
Cabin – adjustment .756
APPENDIX .757
ABBREVIATION LIST 759
List of abbreviations used in the text .759
List of abbreviations used in the circuit diagrams .764
AIR CONDITIONER SYSTEM .765
PRECAUTIONS FOR REFRIGERANT 765
AIR CONDITIONER COMPONENT 766
Specifications of air conditioner 766
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 767
OUTLINE OF REFRIGERATION CYCLE .768
Compression (Compressor) .768
Condensation (Condenser) .768
Expansion (Expansion valve) 768
Evaporation (Evaporator) .769
Relation between refrigerant and cooling trouble .769
AIR CONDITIONER TROUBLESHOOTING CHART 771
Cooling trouble 771
Heating trouble 771
CONNECTION OF SERVICE TOOL .772
METHOD FOR CONNECTING SERVICE TOOL .773
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 774
Precautions for disconnection 774
Precautions for connection .775
HANDLE COMPRESSOR OIL 776
Management of compressor oil (SANDEN: SP-10 for use with R134a) 776
Filling of compressor oil 776
The quantity of compressor oil when the compressor is replaced .777
OTHER 779
HYDRAULIC CIRCUIT DIAGRAM 0
WIRING DIAGRAMS 784
Contents .784
1-0 SYMBOLS SUMMARY, ABBREVIATIONS .785
1-1 HARNESS ARRANGEMENT DETAILS, JOYSTICK BUTTONS 786
1-2 CAN BUS SUMMARY 787
2-0 POWER SUPPLY, STARTER SWITCH .788
2-1 GROUNDING 789
2-2 RELAYB., STARTER, ALTERN., BATTERY, GLOW PLUG 790
2-3 MAIN ENGINE (EGR) RELAYS .791
3-0 AFTERTREATMENT SYS., DPF SENS., OIL PRESS., TRAVEL PED .792
3-1 ECU, ENGINE SENSORS 793
3-2 INJECTOR, FUEL PUMP, AIR CLEANER, WATER SEPA .794
4-0 MONITOR, I/O CONTROLLER64P, BUZZER .795
4-1 KOMTRAX CTRL, SERVICE CONNECTOR 796
4-2 FLUID-SENSORS (OIL, FUEL, COOLANT), SPEED SENS .797
5-0 SEC. ENG. STOP, IMMOBILIZER, DRIVING FUNCT .798
5-1 HST CONTROLLER .799
5-2 HST CONTROLLER INPUTS 800
5-3 CREEP 801
6-0 FAN DRIVE, REVERSE FAN .802
7-0 AIR CONDITIONER, OPERATOR’S SEATI 803
7-1 WASHER, WIPER, REAR WINDOW HEATER, HORN 804
8-0 LIGHTING FRONT .805
8-1 FLASHER 806
8-2 REAR LIGHT, LICENSE PL., BACKUP AL., REAR FLASH 807
8-3 WORK LAMPS .808
8-4 INTERIOR LAMP, ROTATING BEACON, PLUG BOX .809
9-0 DRIVING RANGE, ECSS, OVER CENTER V., AUTO INCH .810
9-1 RETURN TO DIG, QUICK COUPLER, DIFF LOCK 811
W1 WIRING HARNESS LIST .812
W2 CONNECTOR LIST 1 813
W2 CONNECTOR LIST 2 814
W2 CONNECTOR LIST 3 815
W2 CONNECTOR LIST 4 816
W2 CONNECTOR LIST 5 817
W3 PIN LOCATION LIST 1 .818
W3 PIN LOCATION LIST 2 .819
W3 PIN LOCATION LIST 3 .820
WA PIN LOCATION LIST 4 .821
WA PIN LOCATION LIST 5 .822
WA PIN LOCATION LIST 6 .823
WA PIN LOCATION LIST 7 .824
WA PIN LOCATION LIST 8 .825
WA PIN LOCATION LIST 9 .826
WA PIN LOCATION LIST 10 827
WA PIN LOCATION LIST 11 828
WA PIN LOCATION LIST 12 829
WA PIN LOCATION LIST 13 830
WA PIN LOCATION LIST 14 831
WA PIN LOCATION LIST 15 832
WA PIN LOCATION LIST 16 833
WA PIN LOCATION LIST 17 834
WA PIN LOCATION LIST 18 835
WA PIN LOCATION LIST 19 836
WA PIN LOCATION LIST 20 837
WA PIN LOCATION LIST 21 838
WA PIN LOCATION LIST 22 839
WA PIN LOCATION LIST 23 840
WA PIN LOCATION LIST 24 841
WA PIN LOCATION LIST 25 842
WA PIN LOCATION LIST 26 843
WA PIN LOCATION LIST 27 844
WA PIN LOCATION LIST 28 845
WA PARTS LIST 1 846
PARTS LIST 2 .847
PARTS LIST 3 .848
Connector diagram 1 850
Connector diagram 2 851
Connector diagram 3 852
Connector table for the operator‘s cab wiring harness (Part 1/2) .852
Connector diagram 4 853
Connector table for operator‘s cab wiring harness (Part 2/2) . 0

DESCRIPTION:

Komatsu WA80M-8E0 Wheel Loader Shop Manual VENBM08000 –  PDF DOWNLOAD

• WA80M-8E0     H81051 and up

G.B 31/12/24