Komatsu Avance Plus WA180-3MC Wheel Loader Shop Manual CEBM005002 – PDF

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Komatsu Avance Plus WA180-3MC Wheel Loader Shop Manual CEBM005002 – PDF DOWNLOAD

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Komatsu Avance Plus WA180-3MC Wheel Loader Shop Manual CEBM005002 – PDF DOWNLOAD

Language : English
Pages : 490
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu Avance Plus WA180-3MC Wheel Loader Shop Manual CEBM005002 – PDF DOWNLOAD

• SERIAL NUMBERS  WA180-3MC – A81001 and UP

MAIN MENU 0
COVER 1
CONTENTS 2
00 FORWARD 11
HOW TO READ THE SHOP MANUAL 14
VOLUMES 14
DISTRIBUTION AND UPDATING 14
FILING METHOD 14
REVISED EDITION MARK 14
REVISIONS 14
SYMBOLS 14
HOISTING INSTRUCTIONS 15
HOISTING 15
WIRE ROPES 15
COATING MATERIALS 16
STANDARD TIGHTENING TORQUE 18
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS 18
TIGHTENING TORQUE OF HOSE NUTS 19
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS 19
TIGHTENING TORQUE FOR FLARED NUTS 19
ELECTRIC WIRE CODE 20
CLASSIFICATION BY THICKNESS 20
CLASSIFICATION BY COLOR AND CODE 20
CONVERSION TABLES 21
METHOD OF USING THE CONVERSION TABLE 21
SAFETY 11
SAFETY NOTICE 11
IMPORTANT SAFETY NOTICE 11
GENERAL PRECAUTIONS 11
PREPARATIONS FOR WORK 11
PRECAUTIONS DURING WORK 11
01 GENERAL 27
SPECIFICATION DRAWING 28
SPECIFICATIONS 29
LIST OF LUBRICANT AND WATER 34
ENGINE OIL SPECIFICATIONS 35
NORMAL OPERATION 35
ARCTIC OPERATION 35
DIESEL FUEL SPECIFICATIONS 36
COOLANT SPECIFICATIONS 36
GENERAL 36
WATER 36
ANTIFREEZE 37
INHIBITORS/CONDITIONERS 38
10 STRUCTURE AND FUNCTION 43
POWER TRAIN 47
OUTLINE 47
POWER TRAIN SYSTEM 48
OUTLINE 49
TORQUE CONVERTER, TRANSMISSION PIPING 50
OUTLINE 50
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 52
ENGINE LOW IDLING, DIRECTIONAL LEVER AT NEUTRAL, SPEED LEVER AT 2ND 52
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 53
ENGINE STOPPED 53
TORQUE CONVERTER 54
TORQUE CONVERTER OIL FILTER 56
TRANSMISSION 58
CLUTCH 60
REVERSE 1ST CLUTCH 60
FORWARD, 2ND CLUTCH 61
3RD, 4TH CLUTCH 61
FORWARD 1ST 63
FORWARD 2ND 64
FORWARD 3RD 65
FORWARD 4TH 66
REVERSE 1ST 67
TRANSMISSION CONTROL VALVE 68
UPPER VALVE 69
LOWER VALVE 70
TRANSMISSION SOLENOID VALVE 71
TORQUE CONVERTER OUTLET PORT VALVE 72
PILOT REDUCING VALVE 73
TRANSMISSION SOLENOID VALVE 74
PRIORITY VALVE 75
MAIN REGULATOR VALVE 76
QUICK RETURN VALVE 77
MODULATION FILL VALVE 81
DIRECTIONAL SELECTOR SPOOL 83
EMERGENCY MANUAL SPOOL 84
OPERATION OF FORWARD 1ST 86
ACCUMULATOR VALVE 88
TRANSMISSION CONTROL 90
DRIVE SHAFT 91
AXLE 92
FRONT AXLE 92
FRONT DIFFERENTIAL 93
REAR AXLE 94
REAR DIFFERENTIAL 95
TORQUE PROPORTIONING DIFFERENTIAL 97
FINAL DRIVE 98
AXLE MOUNT 100
CENTER HINGE PIN 102
STEERING PIPING 103
STEERING COLUMN 104
PRIORITY VALVE 105
CUSHION VALVE 108
STEERING VALVE (ORBIT-ROLL) 110
CONNECTION BETWEEN HAND PUMP AND SLEEVE 116
BRAKE 118
BRAKE PIPING 118
BRAKE CONTROL 119
BRAKE BOOSTER 120
BRAKE 123
PARKING BRAKE CONTROL 125
PARKING BRAKE 126
HYDRAULIC 128
HYDRAULIC PIPING 128
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM 130
ENGINE LOW IDLING, WORK EQUIPMENT IN “HOLD” 130
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 131
HYDRAULIC TANK 133
OIL FILTER BYPASS VALVE 134
BREATHER 135
PPC VALVE 136
PPC RELIEF VALVE 142
ACCUMULATOR 143
FOR PPC VALVE 143
MAIN CONTROL VALVE 144
2-SPOOL 144
3-SPOOL 146
RELIEF VALVE 148
SAFETY VALVE (WITH SUCTION) 149
SUCTION VALVE 150
BOOM AND BUCKET SPOOL AT NEUTRAL POSITION 151
BOOM SPOOL AT RAISE POSITION 152
BOOM SPOOL AT LOWER POSITION 153
BOOM SPOOL AT FLOAT POSITION 154
BUCKET SPOOL AT TILT BACK POSITION 155
BUCKET SPOOL AT DUMP POSITION 156
WORK EQUIPMENT 157
WORK EQUIPMENT LVER LINKAGE 157
WORK EQUIPMENT LINKAGE 158
BUCKET 160
BUCKET POSITIONER AND BOOM KICK-OUT 161
BUCKET POSITIONER 162
BOOM KICK-OUT 162
PROXIMITY SWITCH 163
ROPS CAB 165
AIR CONDITIONER 166
AIR CONDITIONER AND HEATER PIPING 166
ECSS 167
ECSS HYDRAULIC AND ELECTRICAL CIRCUIT DIAGRAM 168
OPERATION 169
CENTRAL PANEL 170
SENSORS 171
ENGINE OIL PRESSURE 171
BRAKE OIL LEVEL 171
ENGINE SPEED SENSOR 172
ENGINE 173
ENGINE STARTING CIRCUIT 173
ENGINE STOP CIRCUIT 174
AUTOMATIC PREHEATING CIRCUIT 175
QUICK HEATING SYSTEM (QHS) 175
QHS CONTROLLER 177
HEATER RELAY 177
RIBBON HEATER 178
QHS WATER TEMPERATURE SENSOR 178
TRANSMISSION AUTO-SHIFT CONTROL 179
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM 180
SHIFT CONTROL SYSTEM FUNCTION 181
INPUT SIGNALS 181
OUTPUT SIGNALS 182
SHIFT CHARACTERISTICS 183
SAFETY FUNCTION 187
TROUBLESHOOTING 187
TRANSMISSION CONTROLLER 188
CONNECTOR SIGNALS 188
COMBINATION SWITCH 189
TRANSMISSION CUT-OFF FUNCTION 190
PARKING BRAKE FUNCTION 192
KICK-DOWN SWITCH 193
KICK-DOWN ELECTRICAL CIRCUIT 194
KICK-DOWN SWITCH OPERATED 195
KICK-DOWN SWITCH ACTUATION – CANCELED (1) 196
KICK-DOWN SWITCH ACTUATION – CANCELED (2) 197
ELECTRICAL WIRING ILLUSTRATION 199
ELECTRICAL WIRING DIAGRAM (1/5) 201
ELECTRICAL WIRING DIAGRAM (2/5) 203
ELECTRICAL WIRING DIAGRAM (3/5) 205
ELECTRICAL WIRING DIAGRAM (4/5) 207
ELECTRICAL WIRING DIAGRAM (5/5) 209
20 TESTING, ADJUSTING AND TROUBLESHOOTING 213
STANDARD VALUE TABLE 217
ENGINE TABLE – IN CHASSIS 217
CHASSIS TABLE 218
SERVICE TOOLS TABLE 224
ENGINE COMPONENTS 226
ADJUSTING ENGINE STOP MOTOR CABLE 226
ADJUSTING ENGINE STOP SOLENOID 226
MEASURING AND ADJUSTING VALVE CLEARANCE 226
MEASURING BLOW-BY PRESSURE 226
MEASURING COMPRESSION PRESSURE 226
MEASURING COOLANT TEMPERATURE 226
MEASURING ENGINE LUBRICATING OIL PRESSURE 226
MEASURING ENGINE SPEEDS 226
MEASURING EXHAUST COLOR 226
MEASURING EXHAUST GAS TEMPERATURE 226
MEASURING FUEL FILTER INLET RESTRICTION 226
TEST AND ADJUSTING FAN BELT TENSION 226
TEST AND ADJUSTING FUEL INJECTION TIMING 226
ACCELERATOR PEDAL 227
OPERATING FORCE 227
OPERATING ANGLE 228
SPEED LEVER 229
OPERATING FORCE 229
TRAVEL 229
STALL SPEEDS 230
TORQUE CONVERTER STALL SPEED 230
HYDRAULIC STALL SPEED 231
FULL STALL SPEED 231
TORQUE CONVERTER OIL PRESSURE 232
TRANSMISSION OIL PRESSURE 232
EMERGENCY MANUAL SPOOL 234
OPERATION 234
STEERING WHEEL 236
PLAY 236
OPERATING FORCE 236
OPERATING TIME 237
STEERING OIL PRESSURE 238
METHOD OF MEASURING MAIN RELIEF PRESSURE 238
METHOD OF ADJUSTING MAIN RELIEF PRESSURE 239
BRAKE 240
BRAKE PEDAL 240
OPERATING FORCE 240
TRAVEL 240
BRAKE PEDAL LINKAGE 241
TESTING 241
ADJUSTING 241
BRAKE PERFORMANCE 243
BRAKE OIL PRESSURE 244
BRAKE DISC WEAR 245
BLEEDING AIR 246
PARKING BRAKE 247
PARKING BRAKE PERFORMANCE 247
PARKING BRAKE LINKAGE 248
DISC WEAR 249
TESTING 249
MEASURING 250
WORK EQUIPMENT 251
CONTROL LEVER 251
PPC VALVE 252
MEASURING PRESSURE 252
WORK EQUIPMENT HYDRAULIC PRESSURE 254
WORK EQUIPMENT MEASUREMENT 256
HYDRAULIC DRIFT WORK EQUIPMENT 257
BUCKET POSITIONER 258
TESTING 258
ADJUSTING 258
BOOM KICK-OUT (IF EQUIPPED) 259
TESTING 259
ADJUSTING 259
PROXIMITY SWITCH ACTUATION PILOT LAMP (RED) 260
TROUBLESHOOTING GENERAL 261
POINTS TO REMEMBER WHEN TROUBLESHOOTING 263
SEQUENCE OF EVENTS IN TROUBLESHOOTING 265
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 266
PRECAUTIONS WHEN HANDLING ELECTRIC EQUIPMENT 266
HANDLING CONTROL BOX 271
POINTS TO REMEMBER WHEN HANDLING HYDRAULIC EQUIPMENT 272
CHECKS BEFORE TROUBLESHOOTING 274
JUDGEMENT OF POWER TRAIN 275
PRECAUTIONS WHEN TROUBLESHOOTING 276
SAFETY 276
METHODS FOR TROUBLESHOOTING 276
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING 278
PREVENTING RECURRENCE OF TROUBLE 279
HYDRAULIC EQUIPMENT 279
OIL CHECKS 279
CLEANING FRAGMENTS OF DAMAGED PARTS 279
METHOD OF USING TROUBLESHOOTING CHARTS 280
CATEGORY OF TROUBLESHOOTING CODE NUMBER 280
METHOD OF USING TROUBLESHOOTING TABLE FOR EACH TROUBLESHOOTING MODE 280
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 282
METHOD OF USING ENGINE RELATED CHARTS 284
TROUBLESHOOTING ELECTRICAL CONNECTORS 289
CONNECTOR TYPES 290
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 293
ELECTRICAL CIRCUIT DIAGRAMS 301
ENGINE START, STOP SYSTEM 301
PREHEATING SYSTEM 302
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A-MODE) 303
OUTLINE 304
FUNCTION 304
TROUBLESHOOTING 304
FAILURE CODE TABLE 304
TABLE OF TROUBLESHOOTING MODES AND CAUSES 305
A-1 TROUBLESHOOTING CODE [12] 306
F SOLENOID SIGNAL SYSTEM 306
A-2 TROUBLESHOOTING CODE [13] 307
R SOLENOID SIGNAL SYSTEM 307
A-3 TROUBLESHOOTING CODE [14] 308
ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM 308
A-4 TROUBLESHOOTING CODE [16] 309
ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM 309
A-5 TROUBLESHOOTING CODE [20] 310
ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM 310
A-6 TROUBLESHOOTING CODE [21] 311
ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM 311
A-7 TROUBLESHOOTING CODE [22] 312
ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM 312
A-8 TROUBLESHOOTING CODE [23] 313
ABNORMALITY IN ENGINE SPEED SIGNAL SYSTEM 313
A-10 KICK-DOWN SWITCH SYSTEM 314
A-11 TRANSMISSION CUT-OUT SIGNAL SYSTEM 315
A-12 NEUTRALIZER RELAY SIGNAL SYSTEM 316
A-13 BUZZER SIGNAL SYSTEM 317
A-15 CONTROLLER POWER SOURCE SYSTEM 318
TROUBLESHOOTING ELECTRONICALLY CONTROLLED SUSPENSION SYSTM (D-MODE) ECSS 319
ECSS – ELECTRICAL / HYDRAULIC SCHEMATIC 737
ECSS – WORKING CHART 320
ECSS CIRCUIT – REMAINING PRESSURE REMOVAL 321
INSPECTION / ADJUSTMENT 321
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (A-MODE) 303
E-1 ENGINE DOES NOT START 304
A STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START 324
B CHECK FUEL SHUT-OFF SOLENOID 326
E-2 ENGINE DOES NOT STOP 297
E-4 TRANSMISSION IS NOT SET TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (TRANSMISSION CUT-OFF IS NOR 328
E-10 PREHEATING IS NOT CARRIED OUT 330
E-11 PREHEATING REMAINS ACTUATED 332
TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE) 335
S1 STARTING PERFORMANCE IS POOR 337
S2 ENGINE DOES NOT START 338
(1) ENGINE DOES NOT TURN 338
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT 339
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START 340
S-3 ENGINE DOES NOT PICK UP SMOOTHLY 341
S-4 ENGINE STOPS DURING OPERATIONS 342
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 343
S-6 ENGINE LACKS OUTPUT (NO POWER) 344
S-7 EXHAUST GAS IS BLACK 345
S-8 OIL CONSUMPTION IS EXCESSIVE 346
S-9 OIL BECOMES CONTAMINATED QUICKLY 347
S-10 FUEL CONSUMPTION IS EXCESSIVE 348
S-11 OIL IN COOLING WATER 349
S-12 OIL PRESSURE LAMP LIGHTS UP 350
S-13 OIL LEVEL RISES 351
S-14 WATER TEMPERATURE BECOMES TOO HIGH 352
S-15 ABNORMAL NOISE IS MADE 353
S-16 VIBRATION IS EXCESSIVE 354
TROUBLESHOOTING OF HYDRAULIC & MECHANICAL SYSTEMS (T-MODE) 355
T-1 MACHINE DOES NOT START 357
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES 358
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEARS 360
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEARS 361
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 362
T-6 STEERING WHEEL DOES NOT TURN 363
T-7 STEERING IS HEAVY 364
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK 365
T-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING 365
T-10 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT 366
T-11 EXCESSIVE SHOCK TO MACHINE WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT 366
T-12 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR 367
T-13 BRAKE IS NOT RELEASED, BRAKE DRAGS 368
T-14 BOOM DOES NOT RISE 369
T-15 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER 370
T-16 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT 371
T-17 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS) 371
T-18 EXCESSIVE HYDRAULIC DRIFT OF BOOM 371
T-19 BOOM SHAKES DURING OPERATION 372
T-20 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 372
T-21 BUCKET DOES NOT TILT BACK 373
T-22 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER 374
T-23 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 375
T-24 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 375
T-25 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 375
T-26 BUCKET SHAKES DURING LOADING OPERATION 376
T-27 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT 376
T-28 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DOES NOT MOVE SMOOTHLY 377
TESTING, ADJUSTING AND TROUBLESHOOTING AIR CONDITIONER 379
SERVICE TOOLS 381
GAUGE MANIFOLD 381
STRUCTURE AND HANDLING OF GAUGE MANIFOLD 382
CHARGING HOSES 384
GAS LEAK DETECTOR 385
HALIDE TORCH LEAK DETECTOR 385
ELECTRIC LEAK TESTER 387
VALVE FOR SERVICE CANS 389
MAINTENANCE PROCEDURE 390
PRECAUTIONS WHEN REMOVING OR INSTALLING PIPING 390
PROHIBITED WORK 390
OTHER PRECAUTIONS 390
BLEEDING AIR FROM REFRIGERATION CIRCUIT 392
PURPOSE 392
CONNECTING GAUGE MANIFOLD 392
EVACUATION 393
AIR-TIGHTNESS CHECK 393
GAS-LEAK CHECK 394
EVACUATION (REPEATING) 394
CHARGING THE REFRIGERATION CIRCUIT WITH REFRIGERANT 395
CHARGING FROM THE HIGH-PRESSURE SIDE 395
CHARGING FROM THE LOW PRESSURE SIDE 396
WHEN THE AMBIENT TEMPERATURE IS LOW 397
WHEN THE AMBIENT TEMPERATURE IS HIGH 397
REPLACING SERVICE CANS 398
CHECKING THE AMOUNT OF REFRIGERANT 398
REMOVAL OF GAUGE MANIFOLD 400
DISCHARGING THE REFRIGERANT 400
DAILY CHECKS 401
CHECK REFRIGERANT LEVEL 401
CLEANING THE CONDENSER 401
CHECKING THE V-BELT 401
CHECKING OIL LEVEL 402
PROCEDURE FOR CHECKING 402
PROCEDURE FOR CHECKING OIL LEVEL 402
ADDING AND REMOVING OIL 403
ADDING OIL BY EVACUATION 403
TROUBLESHOOTING 404
VISUAL AND ACOUSTICAL CHECKS 404
DEFECTIVE COOLING 405
TROUBLESHOOTING TABLE 407
DEFECTIVE HEATING 409
TROUBLESHOOTING USING GAUGE MANIFOLD 410
PREPARATIONS BEFORE MEASURING 410
INSUFFICIENT REFRIGERANT 410
EXCESSIVE REFRIGERANT OR INSUFFICIENT COOLING OF CONDENSER 411
AIR INSIDE REFRIGERATION SYSTEM 412
MOISTURE IN REFRIGERATING SYSTEM 413
REFRIGERANT DOES NOT CIRCULATE 414
FAILURE OF EXPANSION VALVE (OPEN TO FAR), DEFECTIVE MOUNTING OF HEAT SENSING TUBE 415
DEFECTIVE COMPRESSION BY COMPRESSOR 416
30 DISASSEMBLY AND ASSEMBLY 417
METHOD OF USING MANUAL 421
PRECAUTIONS DURING OPERATION 422
PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK 422
PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK 423
PRECAUTIONS WHEN COMPLETING THE OPERATIONS 424
OTHER PRECAUTIONS 424
SPECIAL TOOL LIST 425
ENGINE COMPONENTS 427
ALTERNATOR ASSEMBLY 427
CYLINDER HEAD ASSEMBLY 427
ENGINE OIL COOLER ASSEMBLY 427
FUEL INJECTION PUMP ASSEMBLY 427
NOZZLE HOLDER ASSEMBLY 427
STARTING MOTOR ASSEMBLY 427
THERMOSTAT ASSEMBLY 427
TURBOCHARGER ASSEMBLY 427
WATER PUMP ASSEMBLY 427
COVERS AND LADDER 428
REMOVAL 428
INSTALLATION 429
ENGINE HOOD 430
REMOVAL 430
INSTALLATION 431
RADIATOR 432
REMOVAL 432
INSTALLATION 435
ENGINE 436
REMOVAL 436
INSTALLATION 443
EXHAUST MUFFLER 444
REMOVAL 444
INSTALLATION 444
AIR CLEANER 445
REMOVAL 445
INSTALLATION 445
TORQUE CONVERTER CHARGING PUMP 446
REMOVAL 446
INSTALLATION 446
TORQUE CONVERTER, TRANSMISSION 447
REMOVAL 447
INSTALLATION 454
TORQUE CONVERTER 456
DISASSEMBLY 456
ASSEMBLY 458
TRANSMISSION 460
DISASSEMBLY 460
DISASSEMBLY OF PARKING BRAKE 469
ASSEMBLY OF PARKING BRAKE 471
ASSEMBLY 474
TRANSMISSION CLUTCH PACK 486
DISASSEMBLY 486
1ST, REVERSE CLUTCH 486
FORWARD, 2ND CLUTCH PACK 488
3RD, 4TH CLUTCH PACK 490
ASSEMBLY 492
1ST, REVERSE CLUTCH 492
FORWARD, 2ND CLUTCH 497
3RD, 4TH CLUTCH 501
TRANSMISSION CONTROL VALVE 506
REMOVAL 506
INSTALLATION 508
DISASSEMBLY 510
ASSEMBLY 512
TRANSMISSION SOLENOID VALVE 515
DISASSEMBLY 515
ASSEMBLY 516
TRANSMISSION ACCUMULATOR VALVE 517
DISASSEMBLY 517
ASSEMBLY 518
DRIVE SHAFT 519
DISASSEMBLY 519
ASSEMBLY 520
FRONT AXLE 521
REMOVAL 521
INSTALLATION 522
REAR AXLE 523
REMOVAL 523
INSTALLATION 527
DIFFERENTIAL 532
DISASSEMBLY 532
ASSEMBLY 536
AXLE HOUSING 546
DISASSEMBLY 546
ASSEMBLY 551
CENTER HINGE PIN 559
REMOVAL 559
INSTALLATION 567
PRIORITY VALVE 576
REMOVAL 576
INSTALLATION 577
STEERING VALVE 578
REMOVAL 578
INSTALLATION 580
DISASSEMBLY 581
DISASSEMBLY OF ROTOR 581
DISASSEMBLY OF CONTROL SIDE 582
ASSEMBLY 584
ASSEMBLY OF CONTROL SIDE 584
ASSEMBLY OF ROTOR 586
MAIN CONTROL VALVE 589
REMOVAL 589
INSTALLATION 591
DISASSEMBLY 592
ASSEMBLY 594
PPC VALVE TO MAIN CONTROL VALVE HYDRAULIC LINES 596
PPC VALVE 598
REMOVAL 598
INSTALLATION 599
STEERING CYLINDER 600
REMOVAL 600
INSTALLATION 602
BRAKE BOOSTER 603
REMOVAL 603
INSTALLATION 605
DISASSEMBLY 606
ASSEMBLY 609
PARKING BRAKE 614
REMOVAL 614
INSTALLATION 616
HYDRAULIC TANK 618
REMOVAL 618
INSTALLATION 619
HYDRAULIC FILTER 620
REMOVAL 620
INSTALLATION 620
STEERING PUMP 621
REMOVAL 621
INSTALLATION 622
BUCKET CYLINDER 623
REMOVAL 623
INSTALLATION 624
BOOM CYLINDER 625
REMOVAL 625
INSTALLATION 626
HYDRAULIC CYLINDER 627
DISASSEMBLY 627
ASSEMBLY 629
ECSS SYSTEM 632
ECSS CIRCUIT – REMAINING PRESSURE REMOVAL 632
ECSS SOLENOID VALVE 633
REMOVAL 633
INSTALLATION 633
ECSS CONTROL VALVE 634
REMOVAL 634
INSTALLATION 634
WORK EQUIPMENT 635
REMOVAL 635
INSTALLATION 638
FUEL TANK 641
REMOVAL 641
INSTALLATION 642
COUNTERWEIGHT 643
REMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS 643
INSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS 643
REMOVAL OF REAR COUNTERWEIGHT 643
INSTALLATION OF REAR COUNTERWEIGHT 644
INSTRUMENT PANEL 645
REMOVAL 645
INSTALLATION 645
AIR CONDITIONING 646
AIR CONDITIONER UNIT 646
REMOVAL 646
INSTALLATION 652
AIR CONDITIONER CONDENSER 653
REMOVAL 653
INSTALLATION 654
DRYER RECEIVER 656
REMOVAL 656
INSTALLATION 656
AIR CONDITIONER COMPRESSOR 658
REMOVAL 658
INSTALLATION 659
40 MAINTENANCE STANDARD 662
ENGINE MOUNT, TRANSMISSION MOUNT 663
TORQUE CONVERTER CHARGING PUMP 665
TORQUE CONVERTER 667
TRANSMISSION 669
TRANSMISSION (1/3) 669
TRANSMISSION (2/3) 673
TRANSMISSION (3/3) 677
REVERSE, 1ST CLUTCH 679
FORWARD, 2ND CLUTCH 681
3RD, 4TH CLUTCH 683
TRANSMISSION CONTROL VALVE 685
UPPER VALVE 685
LOWER VALVE 687
SOLENOID VALVE 689
ACCUMULATOR VALVE 691
DRIVE SHAFT 693
DIFFERENTIAL 695
DIFERENTIAL (1/2) 695
DIFFERENTIAL (2/2) 697
FINAL DRIVE 699
AXLE MOUNT 701
ADDITIONAL COUNTERWEIGHT 703
CENTER HINGE PIN 705
STEERING COLUMN 707
PRIORITY VALVE 709
STEERING CYLINDER MOUNT 710
BRAKE BOOSTER 711
BRAKE 713
PARKING BRAKE 714
HYDRAULIC PUMP (SAL40+14+8) 715
MAIN CONTROL VALVE 716
2-SPOOL VALVE 716
3-SPOOL VALVE 719
HYDRAULIC CYLINDER 722
WORK EQUIPMENT LINKAGE 723
BUCKET 725
BUCKET POSITIONER AND BOOM KICK-OUT 727
90 OTHERS 730
ELECTRICAL WIRING DIAGRAM (1/5) 732
ELECTRICAL WIRING DIAGRAM (2/5) 734
ELECTRICAL WIRING DIAGRAM (3/5) 736
ELECTRICAL WIRING DIAGRAM (4/5) 738
ELECTRICAL WIRING DIAGRAM (5/5) 740

DESCRIPTION:

Komatsu Avance Plus WA180-3MC Wheel Loader Shop Manual CEBM005002 – PDF DOWNLOAD

• SERIAL NUMBERS WA180-3MC – A81001 and UP

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.

G.B  16/12/24