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Komatsu WA180-3L, WA180L-3 Wheel Loader Shop Manual SN A80001 and up, 54001 and up – PDF DOWNLOAD
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Komatsu WA180-3L, WA180L-3 Wheel Loader Shop Manual
Book Code: CEBM001102
SERIAL NUMBERS:
WA180-3L-A80001 and up
WA180L-3-54001 and up
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Description
Komatsu WA180-3L, WA180L-3 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA180-3L, WA180L-3 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA180-3L, WA180L-3
Serial Number: A80001 and up, 54001 and up
Book Code: CEBM001102
Language: English
Pages: 582
File Format: Portable Document Format (PDF)
KOMATSU WA180-3L, WA180L-3 WHEEL LOADER SHOP MANUAL SN A80001 AND UP, 54001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA180-3L, WA180L-3 Wheel Loader Shop Manual
FOREWORD:
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 WA180-3L, WA180L-3 Wheel Loader Shop Manual
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
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