Komatsu Avance Plus WA180PT-3MC Wheel Loader Shop Manual CEBM005201 PDF

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Komatsu Avance Plus WA180PT-3MC Wheel Loader Shop Manual CEBM005201 – PDF DOWNLOAD

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Komatsu Avance Plus WA180PT-3MC Wheel Loader Shop Manual CEBM005201 – PDF DOWNLOAD

Language : English
Pages : 808
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu Avance Plus WA180PT-3MC Wheel Loader Shop Manual CEBM005201 – PDF DOWNLOAD

• SERIAL NUMBERS
• WA180PT-3MC – A88001 and UP

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

DESCRIPTION:

Komatsu Avance Plus WA180PT-3MC Wheel Loader Shop Manual CEBM005201 – PDF DOWNLOAD

• SERIAL NUMBERS
• WA180PT-3MC – A88001 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