Komatsu WA180-3, WA180L-3 Wheel Loader Service Repair Shop Manual - CEBM001102

This complete service repair workshop manual PDF download for the WA180-3, WA180L-3 Komatsu Wheel Loader has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu WA180-3L - SN: A80001 and up
Komatsu WA180L-3 - SN: 54001 and up


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTMENT
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM001102
Total Pages : 582


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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TABLE OF CONTENTS :

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CONTENTS

01 GENERAL
SPECIFICATION DRAWINGS
SPECIFICATIONS
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS
ENGINE OIL SPECIFICATIONS
DIESEL FUEL SPECIFICATIONS
COOLANT SPECIFICATIONS

10 STRUCTURE AND FUNCTION
POWER TRAIN
POWER TRAIN SYSTEM
TORQUE CONVERTER, TRANSMISSION PIPING
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TORQUE CONVERTER
TORQUE CONVERTER OIL FILTER
TRANSMISSION
CLUTCH
REVERSE CLUTCH
FORWARD, 2ND CLUTCH
3RD, 4TH CLUTCH
FORWARD 1ST
FORWARD 2ND
FORWARD 3RD
FORWARD 4TH
REVERSE 1ST
TRANSMISSION CONTROL VALVE
UPPER VALVE
LOWER VALVE
TRANSMISSION SOLENOID VALVE
TORQUE CONVERTER OUTLET PORT VALVE
PILOT REDUCING VALVE
TRANSMISSION SOLENOID VALVE
PRIORITY VALVE
MAIN REGULATOR VALVE
QUICK RETURN VALVE
MODULATION FILL VALVE
DIRECTIONAL SELECTOR SPOOL
EMERGENCY MANUAL SPOOL
OPERATION OF FORWARD 1ST
ACCUMULATOR VALVE
TRANSMISSION CONTROL
DRIVE SHAFT
AXLE
FRONT AXLE
FRONT DIFFERENTIAL
REAR AXLE
REAR DIFFERENTIAL
TORQUE PROPORTIONING DIFFERENTIAL
FINAL DRIVE
AXLE MOUNT
CENTER HINGE PIN
STEERING PIPING
STEERING COLUMN
PRIORITY VALVE
CUSHION VALVE
STEERING VALVE (ORBIT-ROLL)
OPERATION
1.Steering wheel at neutral.
2.Steering wheel turned (turning to left)
CONNECTION BETWEEN HAND PUMP AND SLEEVE
BRAKE PIPING
BRAKE CONTROL
BRAKE BOOSTER
BRAKE
PARKING BRAKE CONTROL
PARKING BRAKE
HYDRAULIC PIPING
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC TANK
OIL FILTER BYPASS VALVE
BREATHER
MAIN CONTROL VALVE
2-SPOOL VALVE
3-SPOOL VALVE
RELIEF VALVE
SAFETY VALVE (WITH SUCTION)
SUCTION VALVE
Boom and bucket spool at NEUTRAL position
Boom spool at RAISE position
Boom spool at LOWER position
Boom spool at FLOAT position
Bucket spool at TILT BACK position
Bucket spool at DUMP position
WORK EQUIPMENT LEVER LINKAGE
WORK EQUIPMENT LINKAGE
BUCKET
BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER
BOOM KICK-OUT
PROXIMITY SWITCH
OPERATION OF THE PROXIMITY SWITCH
Bucket TILT BACK switch
Boom RAISE switch
ACTION OF THE PROXIMITY SWITCH
ROPS CAB
AIR CONDITIONER
AIR CONDITIONER AND HEATER PIPING
ELECTRIC CIRCUIT DIAGRAM
E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)
E.C.S.S. HYDRAULIC, ELECTRICAL CIRCUIT DIAGRAM
OPERATION
ELECTRICAL WIRING ILLUSTRATION
ELECTRICAL WIRING DIAGRAM (1/2)
CENTRAL PANEL (CLUSTER GAUGE)
SENSOR
ENGINE OIL PRESSURE
BRAKE OIL LEVEL
ENGINE STARTING CIRCUIT
ENGINE STOP CIRCUIT
AUTOMATIC PREHEATING CIRCUIT
QUICK HEATING SYSTEM (Q.H.S.)
Q.H.S. CONTROLLER
HEATER RELAY
RIBBON HEATER
Q.H.S. WATER TEMPERATURE SENSOR
ELECTRICAL TRANSMISSION CONTROL
COMBINATION SWITCH
TRANSMISSION CUT-OFF FUNCTION
PARKING BRAKE FUNCTION
KICK-DOWN SWITCH
KICK-DOWN SWITCH
KICK DOWN ELECTRIC CIRCUIT DIAGRAM
KICK-DOWN SWITCH OPERATED
KICK-DOWN SWITCH ACTUATION - CANCELED (1)
KICK-DOWN SWITCH ACTUATION - CANCELED (2)
KICK-DOWN SWITCH ACTUATION - CANCELED (3)

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING
MEASURING ENGINE SPEEDS
MEASURING ENGINE LUBRICATING OIL PRESSURE
MEASURING FUEL FILTER INLET RESTRICTION
MEASURING BLOW-BY PRESSURE
MEASURING COMPRESSION PRESSURE
MEASURING EXHAUST GAS COLOR
MEASURING COOLANT TEMPERATURE
MEASURING AND ADJUSTING VALVE CLEARANCE
MEASURING ACCELERATOR PEDAL
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER
MEASURING STALL SPEEDS
MEASURING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE
METHOD OF OPERATING EMERGENCY MANUAL SPOOL
TESTING AND ADJUSTING STEERING WHEEL
MEASURING STEERING OIL PRESSURE
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL
TESTING AND ADJUSTING BRAKE PEDAL LINKAGE
MEASURING BRAKE PERFORMANCE
TESTING BRAKE OIL PRESSURE
TESTING FOR BRAKE DISC WEAR
BLEEDING AIR FROM BRAKE SYSTEM
MEASURING PARKING BRAKE PERFORMANCE
TESTING AND ADJUSTING PARKING BRAKE LINKAGE
TESTING WEAR OF PARKING BRAKE DISC
MEASURING PARKING BRAKE DISC WEAR
MEASURING WORK EQUIPMENT CONTROL LEVER
MEASURING STROKE OF WORK EQUIPMENT VALVE SPOOL
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
MEASURING WORK EQUIPMENT
TESTING AND ADJUSTING BUCKET POSITIONER
TESTING AND ADJUSTING BOOM KICK-OUT (IF EQUIPPED)
TROUBLESHOOTING TABLE OF CONTENTS
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
HANDLING CONNECTORS
PRECAUTIONS WHEN TROUBLESHOOTING
PREVENTING RECURRENCE OF TROUBLE
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING OF ENGINE SYSTEM
S-1 STARTING PERFORMANCE IS POOR (Starting always takes time)
S-2 Engine does not start
S-3 Engine does not pick up smoothly (Follow up is poor)
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly (hunting)
S-6 Engine lacks output (no power)
S-7 Exhaust gas is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust gas is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in cooling water, or water spurts back, or water level goes down
S-12 Oil pressure lamp lights up (drop in oil pressure)
S-13 Oil level rises
S-14 Water temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED)
POWER TRAIN
T-1 Machine does not start
T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes
T-3 Excessive shock when starting machine or shifting gear
T-4 Excessive time lag when starting machine or shifting gear
T-5 Torque converter oil temperature is high
STEERING SYSTEM
S-1 Steering wheel does not turn
S-2 Steering is heavy
S-3 Steering wheel shakes or there is excessive shock
S-4 Deviates to one side when traveling
S-5 Turning radius is different between left and right
S-6 Excessive shock to machine when steering wheel is turned fully to left or right
BRAKE SYSTEM
A-1 Brakes do not work or braking effect is poor
A-2 Brake is not released, brake drags
WORK EQUIPMENT
H-1 Boom does not rise
H-2 Boom movement is slow or boom lacks lifting power
H-3 When boom is raised, it moves slowly at a certain height
H-4 Bucket cannot be pushed with boom cylinder (bucket floats)
H-5 Excessive hydraulic drift of boom
H-6 Boom shakes during operation
H-7 Boom drops momentarily when control lever is operated from HOLD to RAISE
H-8 Bucket does not tilt back
H-9 Bucket movement is slow or tilt-back lacks power
H-10 Bucket movement becomes slow during tilt-back operation
H-11 Bucket cannot be pushed with bucket cylinder
H-12 Excessive hydraulic drift of bucket
H-13 Bucket shakes during loading operation (Main control valve at HOLD)
H-14 Bucket dumps momentarily when control lever is operated from HOLD to TILT
H-15 Boom, bucket control levers are heavy or do not move smoothly
TROUBLESHOOTING OF EAGLE AIR CONDITIONER

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
1. Precautions when carrying out removal work
2. Precautions when carrying out installation work
3. Precautions when completing the operations
SPECIAL TOOL LIST
STARTING MOTOR
REMOVAL
INSTALLATION
ALTERNATOR
REMOVAL
INSTALLATION
FUEL INJECTION PUMP
REMOVAL
INSTALLATION
ENGINE OIL COOLER
REMOVAL
INSTALLATION
WATER PUMP
REMOVAL
INSTALLATION
NOZZLE HOLDER
REMOVAL
INSTALLATION
THERMOSTAT
REMOVAL
INSTALLATION
TURBOCHARGER
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
ENGINE
REMOVAL
INSTALLATION
ENGINE HOOD
REMOVAL
INSTALLATION
EXHAUST MUFFLER
REMOVAL
INSTALLATION
AIR CLEANER
REMOVAL
INSTALLATION
TORQUE CONVERTER CHARGING PUMP
REMOVAL
INSTALLATION
TORQUE CONVERTER, TRANSMISSION
REMOVAL
INSTALLATION
TORQUE CONVERTER
DISASSEMBLY
ASSEMBLY
TRANSMISSION
DISASSEMBLY
DISASSEMBLY OF PARKING BRAKE
ASSEMBLY OF PARKING BRAKE
ASSEMBLY
TRANSMISSION CLUTCH PACK
I. DISASSEMBLY OF 1ST, REVERSE CLUTCH
II. DISASSEMBLY OF FORWARD, 2ND CLUTCH PACK
Ill. DISASSEMBLY OF 3RD, 4TH CLUTCH PACK
ASSEMBLY OF CLUTCH PACK
l. ASSEMBLY OF 1ST, REVERSE CLUTCH PACK
II.ASSEMBLY OF FORWARD, 2ND CLUTCH PACK
Ill.ASSEMBLY OF 3RD, 4TH CLUTCH PACK
TRANSMISSION CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRANSMISSION SOLENOID VALVE
DISASSEMBLY
ASSEMBLY
TRANSMISSION ACCUMULATOR VALVE
DISASSEMBLY
ASSEMBLY
DRIVE SHAFT
DISASSEMBLY
ASSEMBLY
FRONT AXLE
REMOVAL
INSTALLATION
REAR AXLE
REMOVAL
INSTALLATION
DIFFERENTIAL
DISASSEMBLY
ASSEMBLY
AXLE HOUSING
DISASSEMBLY
ASSEMBLY
CENTER HINGE PIN
REMOVAL
INSTALLATION
PRIORITY VALVE
REMOVAL
INSTALLATION
STEERING VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
MAIN CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
STEERING CYLINDER
REMOVAL
BRAKE BOOSTER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
PARKING BRAKE
REMOVAL
INSTALLATION
HYDRAULIC TANK
REMOVAL
INSTALLATION
HYDRAULIC FILTER
REMOVAL
INSTALLATION
HYDRAULIC STEERING PUMP
REMOVAL
INSTALLATION
BUCKET CYLINDER
REMOVAL
INSTALLATION
BOOM CYLINDER
REMOVAL
INSTALLATION
HYDRAULIC CYLINDER
DISASSEMBLY
ASSEMBLY
WORK EQUIPMENT
REMOVAL
INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
COUNTERWEIGHT
REMOVAL OF LEFT AND RIGHT COUNTERWEIGHTS
INSTALLATION OF LEFT AND RIGHT COUNTERWEIGHTS
REMOVAL OF REAR COUNTERWEIGHT
INSTALLATION OF REAR COUNTERWEIGHT
INSTRUMENT PANEL
REMOVAL
INSTALLATION

40 MAINTENANCE STANDARD
ENGINE MOUNT, TRANSMISSIONMOUNT
TORQUE CONVERTER CHARGING PUMP
TORQUE CONVERTER
TRANSMISSION
TRANSMISSION CONTROL VALVE
ACCUMULATOR VALVE
DRIVE SHAFT
DIFFERENTIAL
FINAL DRIVE
AXLE MOUNT
ADDITIONAL COUNTERWEIGHT
CENTER HINGE PIN
STEERING COLUMN
STEERING CYLINDER MOUNT
PRIORITY VALVE
BRAKE BOOSTER
BRAKE
PARKING BRAKE
HYDRAULIC PUMP
MAIN CONTROL VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT LINKAGE
BUCKET
BUCKET POSITIONER AND BOOM KICK-OUT

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