Komatsu WA180-3 WA180L-3 Wheel Loader Shop Manual CEBM001102 PDF

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Komatsu WA180-3 WA180L-3 Wheel Loader Shop Manual CEBM001102 – PDF DOWNLOAD

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Komatsu WA180-3 WA180L-3 Wheel Loader Shop Manual CEBM001102 – PDF DOWNLOAD 

Language : English
Pages : 582
Downloadable : Yes
File Type : PDF

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Komatsu WA180-3 WA180L-3 Wheel Loader Shop Manual CEBM001102 – PDF DOWNLOAD 

FOREWARD
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 AND ADJUSTING
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.

TABLE OF CONTENTS:

Komatsu WA180-3 WA180L-3 Wheel Loader Shop Manual CEBM001102 – PDF DOWNLOAD 

MAIN MENU 0
CONTENTS 2
01 GENERAL 25
SPECIFICATION DRAWINGS 26
SPECIFICATIONS 27
WEIGHT TABLE 30
FUEL, COOLANT AND LUBRICANTS 31
ENGINE OIL SPECIFICATIONS 32
DIESEL FUEL SPECIFICATIONS 33
COOLANT SPECIFICATIONS 34
10 STRUCTURE AND FUNCTION 39
POWER TRAIN 41
POWER TRAIN SYSTEM 42
TORQUE CONVERTER, TRANSMISSION PIPING 44
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 46
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 47
TORQUE CONVERTER 48
TORQUE CONVERTER OIL FILTER 50
TRANSMISSION 51
CLUTCH 53
REVERSE CLUTCH 53
FORWARD, 2ND CLUTCH 54
3RD, 4TH CLUTCH 54
FORWARD 1ST 56
FORWARD 2ND 57
FORWARD 3RD 58
FORWARD 4TH 59
REVERSE 1ST 60
TRANSMISSION CONTROL VALVE 61
UPPER VALVE 62
LOWER VALVE 63
TRANSMISSION SOLENOID VALVE 64
TORQUE CONVERTER OUTLET PORT VALVE 65
PILOT REDUCING VALVE 66
TRANSMISSION SOLENOID VALVE 67
PRIORITY VALVE 68
MAIN REGULATOR VALVE 69
QUICK RETURN VALVE 70
MODULATION FILL VALVE 74
DIRECTIONAL SELECTOR SPOOL 76
EMERGENCY MANUAL SPOOL 77
OPERATION OF FORWARD 1ST 78
ACCUMULATOR VALVE 80
TRANSMISSION CONTROL 82
DRIVE SHAFT 83
AXLE 84
FRONT AXLE 84
FRONT DIFFERENTIAL 85
REAR AXLE 86
REAR DIFFERENTIAL 87
TORQUE PROPORTIONING DIFFERENTIAL 89
FINAL DRIVE 90
AXLE MOUNT 92
CENTER HINGE PIN 94
STEERING PIPING 95
STEERING COLUMN 96
PRIORITY VALVE 97
CUSHION VALVE 100
STEERING VALVE (ORBIT-ROLL) 102
OPERATION 104
1 Steering wheel at neutral 104
2 Steering wheel turned (turning to left) 106
CONNECTION BETWEEN HAND PUMP AND SLEEVE 108
BRAKE PIPING 110
BRAKE CONTROL 111
BRAKE BOOSTER 112
BRAKE 116
PARKING BRAKE CONTROL 118
PARKING BRAKE 119
HYDRAULIC PIPING 120
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM 122
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 123
HYDRAULIC TANK 124
OIL FILTER BYPASS VALVE 125
BREATHER 126
MAIN CONTROL VALVE 128
2-SPOOL VALVE 128
3-SPOOL VALVE 130
RELIEF VALVE 132
SAFETY VALVE (WITH SUCTION) 133
SUCTION VALVE 134
Boom and bucket spool at NEUTRAL position 135
Boom spool at RAISE position 136
Boom spool at LOWER position 137
Boom spool at FLOAT position 138
Bucket spool at TILT BACK position 139
Bucket spool at DUMP position 140
WORK EQUIPMENT LEVER LINKAGE 141
WORK EQUIPMENT LINKAGE 142
BUCKET 144
BUCKET POSITIONER AND BOOM KICK-OUT 145
BUCKET POSITIONER 146
BOOM KICK-OUT 146
PROXIMITY SWITCH 147
OPERATION OF THE PROXIMITY SWITCH 148
Bucket TILT BACK switch 148
Boom RAISE switch 148
ACTION OF THE PROXIMITY SWITCH 148
ROPS CAB 149
AIR CONDITIONER 150
AIR CONDITIONER AND HEATER PIPING 150
ELECTRIC CIRCUIT DIAGRAM 151
E C S S (ELECTRONIC CONTROLLED SUSPENSION SYSTEM) 152
E C S S HYDRAULIC, ELECTRICAL CIRCUIT DIAGRAM 153
OPERATION 154
ELECTRICAL WIRING ILLUSTRATION 157
ELECTRICAL WIRING DIAGRAM (1/2) 158
CENTRAL PANEL (CLUSTER GAUGE) 160
SENSOR 161
ENGINE OIL PRESSURE 161
BRAKE OIL LEVEL 161
ENGINE STARTING CIRCUIT 162
ENGINE STOP CIRCUIT 163
AUTOMATIC PREHEATING CIRCUIT 164
QUICK HEATING SYSTEM (Q H S ) 164
Q H S CONTROLLER 166
HEATER RELAY 166
RIBBON HEATER 167
Q H S WATER TEMPERATURE SENSOR 167
ELECTRICAL TRANSMISSION CONTROL 168
COMBINATION SWITCH 169
TRANSMISSION CUT-OFF FUNCTION 170
PARKING BRAKE FUNCTION 172
KICK-DOWN SWITCH 173
KICK-DOWN SWITCH 173
KICK DOWN ELECTRIC CIRCUIT DIAGRAM 174
KICK-DOWN SWITCH OPERATED 175
KICK-DOWN SWITCH ACTUATION – CANCELED (1) 176
KICK-DOWN SWITCH ACTUATION – CANCELED (2) 177
KICK-DOWN SWITCH ACTUATION – CANCELED (3) 178
20 TESTING AND ADJUSTING 179
STANDARD VALUE TABLE FOR ENGINE 180
STANDARD VALUE TABLE FOR CHASSIS 182
TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING 186
MEASURING ENGINE SPEEDS 188
MEASURING ENGINE LUBRICATING OIL PRESSURE 189
MEASURING FUEL FILTER INLET RESTRICTION 189
MEASURING BLOW-BY PRESSURE 189
MEASURING COMPRESSION PRESSURE 190
MEASURING EXHAUST GAS COLOR 191
MEASURING COOLANT TEMPERATURE 192
MEASURING AND ADJUSTING VALVE CLEARANCE 192
MEASURING ACCELERATOR PEDAL 193
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER 195
MEASURING STALL SPEEDS 196
MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE 198
METHOD OF OPERATING EMERGENCY MANUAL SPOOL 200
TESTING AND ADJUSTING STEERING WHEEL 202
MEASURING STEERING OIL PRESSURE 204
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL 206
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE 207
MEASURING BRAKE PERFORMANCE 209
TESTING BRAKE OIL PRESSURE 210
TESTING FOR BRAKE DISC WEAR 211
BLEEDING AIR FROM BRAKE SYSTEM 212
MEASURING PARKING BRAKE PERFORMANCE 213
TESTING AND ADJUSTING PARKING BRAKE LINKAGE 214
TESTING WEAR OF PARKING BRAKE DISC 215
MEASURING PARKING BRAKE DISC WEAR 216
MEASURING WORK EQUIPMENT CONTROL LEVER 217
MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL 220
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 221
MEASURING WORK EQUIPMENT 223
TESTING AND ADJUSTING BUCKET POSITIONER 225
TESTING AND ADJUSTING BOOM KICK-OUT (IF EQUIPPED) 226
TROUBLESHOOTING TABLE OF CONTENTS 229
POINTS TO REMEMBER WHEN TROUBLESHOOTING 231
SEQUENCE OF EVENTS IN TROUBLESHOOTING 232
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 233
CHECKS BEFORE TROUBLESHOOTING 241
HANDLING CONNECTORS 242
PRECAUTIONS WHEN TROUBLESHOOTING 243
PREVENTING RECURRENCE OF TROUBLE 245
METHOD OF USING TROUBLESHOOTING CHARTS 247
TROUBLESHOOTING OF ENGINE SYSTEM 257
S-1 STARTING PERFORMANCE IS POOR (Starting always takes time) 258
S-2 Engine does not start 259
S-3 Engine does not pick up smoothly (Follow up is poor) 262
S-4 Engine stops during operations 263
S-5 Engine does not rotate smoothly (hunting) 264
S-6 Engine lacks output (no power) 265
S-7 Exhaust gas is black (incomplete combustion) 266
S-8 Oil consumption is excessive (or exhaust gas is blue) 267
S-9 Oil becomes contaminated quickly 268
S-10 Fuel consumption is excessive 269
S-11 Oil is in cooling water, or water spurts back, or water level goes down 270
S-12 Oil pressure lamp lights up (drop in oil pressure) 271
S-13 Oil level rises 272
S-14 Water temperature becomes too high (overheating) 273
S-15 Abnormal noise is made 274
S-16 Vibration is excessive 275
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) 277
POWER TRAIN 278
T-1 Machine does not start 279
T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes 280
T-3 Excessive shock when starting machine or shifting gear 282
T-4 Excessive time lag when starting machine or shifting gear 283
T-5 Torque converter oil temperature is high 284
STEERING SYSTEM 285
S-1 Steering wheel does not turn 285
S-2 Steering is heavy 286
S-3 Steering wheel shakes or there is excessive shock 287
S-4 Deviates to one side when traveling 288
S-5 Turning radius is different between left and right 288
S-6 Excessive shock to machine when steering wheel is turned fully to left or right 288
BRAKE SYSTEM 289
A-1 Brakes do not work or braking effect is poor 289
A-2 Brake is not released, brake drags 290
WORK EQUIPMENT 291
H-1 Boom does not rise 291
H-2 Boom movement is slow or boom lacks lifting power 292
H-3 When boom is raised, it moves slowly at a certain height 293
H-4 Bucket cannot be pushed with boom cylinder (bucket floats) 293
H-5 Excessive hydraulic drift of boom 293
H-6 Boom shakes during operation 293
H-7 Boom drops momentarily when control lever is operated from HOLD to RAISE 294
H-8 Bucket does not tilt back 295
H-9 Bucket movement is slow or tilt-back lacks power 296
H-10 Bucket movement becomes slow during tilt-back operation 297
H-11 Bucket cannot be pushed with bucket cylinder 297
H-12 Excessive hydraulic drift of bucket 297
H-13 Bucket shakes during loading operation (Main control valve at HOLD) 298
H-14 Bucket dumps momentarily when control lever is operated from HOLD to TILT 298
H-15 Boom, bucket control levers are heavy or do not move smoothly 299
TROUBLESHOOTING OF EAGLE AIR CONDITIONER 301
30 DISASSEMBLY AND ASSEMBLY 306
METHOD OF USING MANUAL 310
PRECAUTIONS WHEN CARRYING OUT OPERATION 311
1 Precautions when carrying out removal work 311
2 Precautions when carrying out installation work 312
3 Precautions when completing the operations 313
SPECIAL TOOL LIST 314
STARTING MOTOR 316
REMOVAL 316
INSTALLATION 316
ALTERNATOR 317
REMOVAL 317
INSTALLATION 317
FUEL INJECTION PUMP 318
REMOVAL 318
INSTALLATION 318
ENGINE OIL COOLER 319
REMOVAL 319
INSTALLATION 319
WATER PUMP 320
REMOVAL 320
INSTALLATION 320
NOZZLE HOLDER 321
REMOVAL 321
INSTALLATION 321
THERMOSTAT 322
REMOVAL 322
INSTALLATION 322
TURBOCHARGER 323
REMOVAL 323
INSTALLATION 323
CYLINDER HEAD 324
REMOVAL 324
INSTALLATION 324
RADIATOR 325
REMOVAL 325
INSTALLATION 328
ENGINE 329
REMOVAL 329
INSTALLATION 336
ENGINE HOOD 337
REMOVAL 337
INSTALLATION 338
EXHAUST MUFFLER 339
REMOVAL 339
INSTALLATION 339
AIR CLEANER 340
REMOVAL 340
INSTALLATION 340
TORQUE CONVERTER CHARGING PUMP 341
REMOVAL 341
INSTALLATION 341
TORQUE CONVERTER, TRANSMISSION 342
REMOVAL 342
INSTALLATION 349
TORQUE CONVERTER 350
DISASSEMBLY 350
ASSEMBLY 352
TRANSMISSION 354
DISASSEMBLY 354
DISASSEMBLY OF PARKING BRAKE 363
ASSEMBLY OF PARKING BRAKE 365
ASSEMBLY 368
TRANSMISSION CLUTCH PACK 380
I DISASSEMBLY OF 1ST, REVERSE CLUTCH 380
II DISASSEMBLY OF FORWARD, 2ND CLUTCH PACK 382
Ill DISASSEMBLY OF 3RD, 4TH CLUTCH PACK 384
ASSEMBLY OF CLUTCH PACK 386
l ASSEMBLY OF 1ST, REVERSE CLUTCH PACK 386
II ASSEMBLY OF FORWARD, 2ND CLUTCH PACK 391
Ill ASSEMBLY OF 3RD, 4TH CLUTCH PACK 395
TRANSMISSION CONTROL VALVE 400
REMOVAL 400
INSTALLATION 401
DISASSEMBLY 403
ASSEMBLY 405
TRANSMISSION SOLENOID VALVE 407
DISASSEMBLY 407
ASSEMBLY 407
TRANSMISSION ACCUMULATOR VALVE 408
DISASSEMBLY 408
ASSEMBLY 409
DRIVE SHAFT 410
DISASSEMBLY 410
ASSEMBLY 412
FRONT AXLE 414
REMOVAL 414
INSTALLATION 415
REAR AXLE 416
REMOVAL 416
INSTALLATION 420
DIFFERENTIAL 425
DISASSEMBLY 425
ASSEMBLY 429
AXLE HOUSING 439
DISASSEMBLY 439
ASSEMBLY 444
CENTER HINGE PIN 452
REMOVAL 452
INSTALLATION 460
PRIORITY VALVE 469
REMOVAL 469
INSTALLATION 470
STEERING VALVE 471
REMOVAL 471
INSTALLATION 473
DISASSEMBLY 474
ASSEMBLY 477
MAIN CONTROL VALVE 482
REMOVAL 482
INSTALLATION 484
DISASSEMBLY 485
ASSEMBLY 487
STEERING CYLINDER 489
REMOVAL 489
BRAKE BOOSTER 491
REMOVAL 491
INSTALLATION 493
DISASSEMBLY 494
ASSEMBLY 497
PARKING BRAKE 502
REMOVAL 502
INSTALLATION 504
HYDRAULIC TANK 505
REMOVAL 505
INSTALLATION 506
HYDRAULIC FILTER 507
REMOVAL 507
INSTALLATION 507
HYDRAULIC STEERING PUMP 508
REMOVAL 508
INSTALLATION 509
BUCKET CYLINDER 510
REMOVAL 510
INSTALLATION 511
BOOM CYLINDER 512
REMOVAL 512
INSTALLATION 513
HYDRAULIC CYLINDER 514
DISASSEMBLY 514
ASSEMBLY 516
WORK EQUIPMENT 518
REMOVAL 518
INSTALLATION 521
FUEL TANK 524
REMOVAL 524
INSTALLATION 525
COUNTERWEIGHT 526
REMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS 526
INSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS 526
REMOVAL OF REAR COUNTERWEIGHT 526
INSTALLATION OF REAR COUNTERWEIGHT 527
INSTRUMENT PANEL 528
REMOVAL 528
INSTALLATION 528
40 MAINTENANCE STANDARD 530
ENGINE MOUNT, TRANSMISSIONMOUNT 532
TORQUE CONVERTER CHARGING PUMP 533
TORQUE CONVERTER 534
TRANSMISSION 535
TRANSMISSION CONTROL VALVE 547
ACCUMULATOR VALVE 551
DRIVE SHAFT 552
DIFFERENTIAL 554
FINAL DRIVE 557
AXLE MOUNT 559
ADDITIONAL COUNTERWEIGHT 560
CENTER HINGE PIN 561
STEERING COLUMN 563
STEERING CYLINDER MOUNT 564
PRIORITY VALVE 565
BRAKE BOOSTER 566
BRAKE 567
PARKING BRAKE 568
HYDRAULIC PUMP 569
MAIN CONTROL VALVE 571
HYDRAULIC CYLINDER 575
WORK EQUIPMENT LINKAGE 577
BUCKET 579
BUCKET POSITIONER AND BOOM KICK-OUT 580

S.V 13/12/24