Komatsu Wheel Loader WA180-3 Shop Manual SEBM005804 PDF

MACHINE MODEL
WA180-3

SERIAL NUMBER
50001 and up

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 chapters; these chapters are further divided into the each main group of components.

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.

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.

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.

This section gives the judgement standards when inspecting disassembled parts.

MACHINE MODEL
WA180-3

SERIAL NUMBER
50001 and up

COVER 1
CONTENTS 2
01 GENERAL 23
GENERAL ASSEMBLY DRAWING 24
SPECIFICATIONS 26
WEIGHT TABLE 29
LIST OF LUBRICANT AND WATER 31
10 STRUCTURE AND FUNCTION 33
POWER TRAIN 34
POWER TRAIN SYSTEM 35
TORQUE CONVERTER, TRANSMISSION PIPING 37
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 38
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 39
TORQUE CONVERTER 42
TORQUE CONVERTER OIL FILTER 44
TRANSMISSION 45
TRANSMISSION CONTROL VALVE 56
TRANSMISSION CONTROL 80
DRIVE SHAFT 81
AXLE 82
FINAL DRIVE 88
AXLE MOUNT 89
CENTER HINGE PIN 91
STEERING PIPING 92
STEERING COLUMN 93
PRIORITY VALVE 94
CUSHION VALVE 97
STEERING VALVE (ORBIT-ROLL) 98
BRAKE PIPING106
BRAKE CONTROL 107
BRAKE BOOSTER108
BRAKE112
PARKING BRAKE CONTROL 114
PARKING BRAKE115
HYDRAULIC PIPING116
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM118
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM119
HYDRAULIC TANK120
MAIN CONTROL VALVE123
WORK EQUIPMENT LEVER LINKAGE136
WORK EQUIPMENT LINKAGE137
BUCKET139
BUCKET POSITIONER AND BOOM KICK-OUT140
PROXIMITY SWITCH142
CANOPY144
ROPS CAB145
ROPS CANOPY146
AIR CONDITIONER147
TRAVEL DAMPER SYSTEM149
ELECTRICAL WIRING DIAGRAM154
ELECTRICAL CIRCUIT DIAGRAM (1/2)155
AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM (2/2)159
CENTRAL PANEL (CLUSTER GAUGE)161
SENSOR162
ENGINE STARTING CIRCUIT163
ENGINE STOP CIRCUIT165
FUEL CUT-OFF SOLENOID167
AUTOMATIC PREHEATING CIRCUIT (QGS CIRCUIT)168
AUTOMATIC PREHEATING CIRCUIT (QHS CONTROLLER)171
AUTOMATIC AIR BLEED MECHANISM175
ELECTRICAL TRANSMISSION CONTROL176
COMBINATION SWITCH177
TRANSMISSION CUT-OFF FUNCTION178
PARKING BRAKE FUNCTION180
KICK-DOWN SWITCH181
20 TESTING AND ADJUSTING187
STANDARD VALUE TABLE FOR ENGINE188
STANDARD VALUE TABLE FOR CHASSIS190
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING193
ADJUSTING VALVE CLEARANCE195
MEASURING COMPRESSION PRESSURE197
TESTING AND ADJUSTING FUEL INJECTION TIMING198
MEASURING EXHAUST COLOR200
MEASURING BLOW-BY PRESSURE201
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)203
MEASURING ENGINE OIL PRESSURE204
TESTING AND ADJUSTING FAN BELT TENSION205
MEASURING ENGINE SPEED206
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE208
ADJUSTING ENGINE STOP SOLENOID210
MEASURING ACCELERATOR PEDAL211
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER213
MEASURING STALL SPEED214
MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE216
METHOD OF OPERATING EMERGENCY MANUAL SPOOL 218
TESTING AND ADJUSTING STEERING WHEEL220
MEASURING STEERING OIL PRESSURE223
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL225
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE226
MEASURING BRAKE PERFORMANCE228
MEASURING BRAKE OIL PRESSURE229
TESTING FOR BRAKE DISC WEAR230
BLEEDING AIR FROM BRAKE SYSTEM231
MEASURING PARKING BRAKE PERFORMANCE232
TESTING AND ADJUSTING PARKING BRAKE LINKAGE233
TESTING PARKING BRAKE DISC WEAR234
MEASURING PARKING BRAKE DISC WEAR235
MEASURING WORK EQUIPMENT CONTROL LEVER236
MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL239
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE240
MEASURING WORK EQUIPMENT242
TESTING AND ADJUSTING BUCKET POSITIONER244
TESTING AND ADJUSTING BOOM KICK-OUT245
TROUBLESHOOTING247
USING TROUBLESHOOTING CHARTS FOR ENGINE-RELATED FAILURE248
POINTS TO REMEMBER WHEN TROUBLESHOOTING252
TROUBLESHOOTIING OF ENGINE (S6D95L) SYSTEM (S MODE)[SERIAL NO50001-52999]253
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)254
S-2 ENGINE DOES NOT START255
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)258
S-4 ENGINE STOPS DURING OPERATIONS259
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)260
S-6 ENGINE LACKS OUTPUT (NO POWER)261
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)262
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)263
S-9 OIL BECOMES CONTAMINATED QUICKLY264
S-10 FUEL CONSUMPTION IS EXCESSIVE265
S-11 OIL IS COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN266
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)267
S-13 OIL LEVEL RISES268
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)269
S-15 ABNORMAL NOISE IS MADE270
S-16 VIBRATION IS EXCESSIVE271
TROUBLESHOOTING OF ENGINE (S6D102E) SYSTEM (S MODE)[SERIAL NO53001 AND UP]272
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)273
S-2 ENGINE DOES NOT START274
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)277
S-4 ENGINE STOPS DURING OPERATIONS278
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)279
S-6 ENGINE LACKS OUTPUT (NO POWER)280
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)281
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)282
S-9 OIL BECOMES CONTAMINATED QUICKLY283
S-10 FUEL CONSUMPTION IS EXCESSIVE284
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN285
S-12 OIL PRESSURE LAMP LIGHTS UO (DROP IN OIL PRESSURE)286
S-13 OIL LEVEL RISES287
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)288
S-15 ABNORMAL NOISE IS MADE289
S-16 VIBRATION IS EXCESSIVE290
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED)291
POWER TRAIN292
T-1 MACHINE DOES NOT START292
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES294
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR296
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR297
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH298
STEERING SYSTEM299
S-1 STEERING WHEEL DOES NOT TURN299
S-2 STEERING IS HEAVY300
S-3 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK301
S-4 DEVIATES TO ONE SIDE WHEN TRAVELING302
S-5 TURNING RADIUS IS DIFFERENT BETWEEN LEFT AND RIGHT 302
S-6 EXCESSIVE SHOCK TO MACHINE WHEN STEERING WHEEL IS TURNED FULLY TO LEFT OR RIGHT302
BRAKE SYSTEM303
A-1 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR303
A-2 BRAKE IS NOT RELEASED, BRAKE DRAGS304
WORK EQUIPMENT 305
H-1 BOOM DOES NOT RISE305
H-2 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER306
H-3 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT307
H-4 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)307
H-5 EXCESSIVE HYDRAULIC DRIFT OR BOOM307
H-6 BOOM SHAKES DURING OPERATION307
H-7 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE308
H-8 BUCKET DOES NOT TILT BACK309
H-9 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER310
H-10 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION311
H-11 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER311
H-12 EXCESSIVE HYDRAULIC DRIFT OF BUCKET311
H-13 BUCKET SHAKES DURING LOADING OPERATION312
H-14 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT312
H-15 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY 313
30 DISASSEMBLY AND ASSEMBLY314
METHOD OF USING MANUAL316
PRECAUTIONS WHEN CARRYING OUT OPERATION317
SPECAIL TOOL LIST319
STARTING MOTOR321
REMOVAL AND INSTALLATION321
ALTERNATOR322
REMOVAL AND INSTALLATION322
FUEL INJECTION PUMP324
REMOVAL 324
INSTALLATION325
ENGINE OIL COOLER331
REMOVAL AND INSTALLATION331
WATER PUMP333
REMOVAL AND INSTALLATION333
NOZZLE HOLDER335
REMOVAL AND INSTALLATION335
THERMOSTAT338
REMOVAL AND INSTALLATION338
TURBOCHARGER340
REMOVAL AND INSTALLATION340
CYLINDER HEAD342
REMOVAL342
INSTALLATION345
RADIATOR355
REMOVAL355
INSTALLATION358
RADIATOR, HYDRAULIC COOLER359
REMOVAL359
INSTALLATION360
ENGINE361
REMOVAL361
INSTALLATION364
TORQUE CONVERTER CHARGING PUMP369
REMOVAL AND INSTALLATION369
TORQUE CONVERTER, TRANSMISSION 370
REMOVAL370
INSTALLATION377
TORQUE CONVERTER378
DISASSEMBLY378
ASSEMBLY380
TRANSMISSION382
DISASSEMBLY382
ASSEMBLY393
CLUTCH PACK408
DISASSEMBLY408
ASSEMBLY414
TRANSMISSION CONTROL VALVE428
REMOVAL428
INSTALLATION429
DISASSEMBLY430
ASSEMBLY432
TRANSMISSION SOLENOID VALVE434
DISASSEMBLY AND ASSEMLBY434
TRANSMISSION ACCUMULATOR VALVE435
DISASSEMBLY435
ASSEMBLY436
DRIVE SHAFT437
DISASSEMBLY437
ASSEMBLY439
FRONT AXLE441
REMOVAL441
INSTALLATION442
REAR AXLE443
REMOVAL443
INSTALLATION447
DIFFERENTIAL452
DISASSEMBLY452
ASSEMBLY456
AXLE HOUSING466
DISASSEMBLY466
ASSEMBLY471
CENTER HINGE PIN479
REMOVAL479
INSTALLATION487
PRIORITY VALVE496
REMOVAL496
INSTALLATION497
STEERING VALVE498
REMOVAL498
INSTALLATION500
DISASSEMBLY501
ASSEMBLY504
STEERING CYLINDER509
REMOVAL509
INSTALLATION510
BRAKE BOOSTER511
REMOVAL511
INSTALLATION513
DISASSEMBLY514
ASSEMBLY517
PARKING BRAKE522
REMOVAL522
INSTALLATION524
HYDRAULIC TANK525
REMOVAL525
INSTALLATION526
HYDRAULIC FILTER527
REMOVAL AND INSTALLATION527
HYDRAULIC, STEERING PUMP528
REMOVAL528
INSTALLATION529
MAIN CONTROL VALVE530
REMOVAL530
INSTALLATION532
DISASSEMBLY533
ASSEMBLY535
BUCKET CYLINDER537
REMOVAL537
INSTALLATION538
BOOM CYLINDER539
REMOVAL539
INSTALLATION540
HYDRAULIC CYLINDER541
DISASSEMBLY541
ASSEMBLY543
WORK EQUIPMENT 545
REMOVAL545
INSTALLATION548
FUEL TANK551
REMOVAL551
INSTALLATION552
COUNTERWEIGHT555
REMOVAL AND INSTALLATION555
INSTRUMENT PANEL556
REMOVAL AND INSTALLATION556
ENGINE HOOD557
REMOVAL AND INSTALLATION557
40 MAINTENANCE STANDARD558
ENGINE MOUNT, TRANSMISSION MOUNT559
TORQUE CONVERTER CHARGING PUMP561
TORQUE CONVERTER562
TRANSMISSION563
TRANSMISSION CONTROL VALVE577
ACCUMULATOR VALVE583
DRIVE SHAFT584
DIFFERENTIAL 585
FINAL DRIVE588
AXLE MOUNT590
CENTER HINGE PIN591
STEERING COLUMN593
PRIORITY VALVE594
STEERING CYLINDER MOUNT595
BRAKE BOOSTER596
BRAKE597
PARKING BRAKE598
HYDRAULIC PUMP599
MAIN CONTROL VALVE600
HYDRAULIC CYLINDER604
WORK EQUIPMENT LINKAGE605
BUCKET607
BUCKET POSITIONER AND BOOM KICK-OUT608