Komatsu wa180 3 wheel loader service repair manual sna80001 and up

00-2
CONTENTS
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

SAFETY SAFETY NOTICE
00-5
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repair
techniques recommended and described in this manual are both effective and safe methods of operation.
Some of these operations require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises
or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS clean and make sure that there is no dirt or oil on the
Mistakes in operation are extremely dangerous. Read the Never smoke while working.
OPERATION & MAINTENANCE MANUAL carefully
BEFORE operating the machine. PREPARATIONS FOR WORK
1. Before carrying out any greasing or repairs, read all 7. Before adding oil or making repairs, park the
the precautions given on the decals which are fixed to machine on hard, level ground, and block the
the machine. wheels or tracks to prevent the machine from
2. When carrying out any operation, always wear safety
shoes and helmet. Do not wear loose work clothes, 8. Before starting work, lower blade, ripper, bucket or
or clothes with buttons missing. any other work equipment to the ground. If this is
not possible, insert the safety pin or use blocks to
! Always wear safety glasses when hitting parts
with a hammer.
! Always wear safety glasses when grinding parts
with a grinder, etc.
3. If welding repairs are needed, always have a trained,
experienced welder carry out the work. When
carrying out welding work, always wear welding
gloves, apron, glasses, cap and other clothes suited
for welding work.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers
before starting any step of the operation. Before
starting work, hang UNDER REPAIR signs on the
controls in the operator's compartment.
5. Keep all tools in good condition and learn the correct
way to use them.
6. Decide a place in the repair workshop to keep tools
and removed parts. Always keep the tools and parts
in their correct places. Always keep the work area
floor. Smoke only in the areas provided for smoking.
moving.
prevent the work equipment from falling. In
addition, be sure to lock all the control levers and
hang warning signs on them.
9. When disassembling or assembling, support the
machine with blocks, jacks or stands before
starting work.
10. Remove all mud and oil from the steps or other
places used to get on and off the machine. Always
use the handrails, ladders or steps when getting on
or off the machine. Never jump on or off the
machine. If it is impossible to use the handrails,
ladders or steps, use a stand to provide safe
footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or
hydraulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out. Before
disconnecting or removing components of the oil,

SAFETY SAFETY NOTICE
00-6
water or air circuits, first remove the pressure completely 18. As a general rule, do not use gasoline to wash
from the circuit. parts. In particular, use only the minimum of
12. The water and oil in the circuits are hot when the
engine is stopped, so be careful not to get burned. 19. Be sure to assemble all parts again in their original
Wait for the oil and water to cool before carrying out places. Replace any damaged part with new parts.
any work on the oil or water circuits.
13. Before starting work, remove the leads from the
battery. ALWAYS remove the lead from the negative
(-) terminal first.
14. When raising heavy components, use a hoist or
crane. Check that the wire rope, chains and hooks
are free from damage. Always use lifting equipment
which has ample capacity. Install the lifting
equipment at the correct places. Use a hoist or crane
and operate slowly to prevent the component from
hitting any other part. Do not work with any part still
raised by the hoist or crane.
15. When removing covers which are under internal
pressure or under pressure from a spring, always
leave two bolts in position on opposite sides. Slowly
release the pressure, then slowly loosen the bolts to
remove.
16. When removing components, be careful not to break
or damage the wiring, Damaged wiring may cause
electrical fires.
17. When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips on to the floor, wipe
it up immediately. Fuel or oil on the floor can cause
you to slip, or can even start fires.
gasoline when washing electrical parts.
! When installing hoses and wires, be sure that
they will not be damaged by contact with other
parts when the machine is being operated.
20. When installing high pressure hoses, make sure
that they are not twisted. Damaged tubes are
dangerous, so be extremely careful when installing
tubes for high pressure circuits. Also check that
connecting parts are correctly installed.
21. When assembling or installing parts, always use
the specified tightening torques. When installing
protective parts such as guards, or parts which
vibrate violently or rotate at high speed, be
particularly careful to check that they are installed
correctly.
22. When aligning two holes, never insert your fingers
or hand. Be careful not to get your fingers caught
in a hole.
23. When measuring hydraulic pressure, check that
the measuring tool is correctly assembled before
taking any measurements.
24. Take care when removing or installing the tracks of
track-type machines. When removing the track, the
track separates suddenly, so never let anyone
stand at either end of the track.

FOREWARD GENERAL
00-7
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.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance
notice. Contact your distributor for the latest information.

FOREWARD HOW TO READ THE SHOP MANUAL
00-8
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying out
repairs. They are divided as follows:
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series
Electrical volume: Each issued as one to cover all
models
Attachment volume: Each issued as one to cover all
models
These various volumes are designed to avoid duplication
of information. Therefore to deal with all repairs for any
model, it is necessary that chassis, engine electrical and
attachment be available.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be sent
to your distributors. Get the most up-to-date information
before you start any work.
FILING METHOD
1. See the page number on the bottom of the page. File
the pages in correct order.
2. Following examples show how to read the page
number:
Example 1 (Chassis volume):
10 - 3
Item number (10. Structure and
Function)
Consecutive page number for
each item
Example 2 (Engine volume):
Refer to the pertinent engine manual.
3. Additional pages: Additional pages are indicated by a
hyphen (-) and numbered after the page number. File
as in the example.
Example:
10-4 10-4-1
A
Added pages
10-4-2
10-5
When a manual is revised, an edition mark ( ....) is
âãä
recorded on the bottom outside corner of the pages.
REVISIONS
Revised pages are shown at the LIST OF REVISED
PAGES between the title page and SAFETY page.
SYMBOLS
So that the shop manual can be of ample practical use,
important places for safety and quality are marked with
the following symbols.
Symbol Item Remarks
Safety
Special safety precautions are
necessary when performing the
work.
Caution
Special technical precautions or
other precautions for preserving
standards are necessary when
performing the work.
Weight
Weight of parts or systems.
Caution necessary when selecting
hoisting wire or when working
posture is important, etc.
Tightening
torque
Places that require special
attention for tightening torque
during assembly.
Coat
Places to be coated with adhesives
and lubricants etc.
Oil, water
Places where oil, water or fuel
must be added, and the capacity.
Drain
Places where oil or water must be
drained, and quantity to be
drained.

FOREWARD HOISTING INSTRUCTIONS
00-9
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25 kg or more) must be lifted with
a hoist etc. In the DISASSEMBLY AND
ASSEMBLY section, every part weighing 25 kg or
more is indicated clearly with the symbol
! If a part cannot be smoothly removed from the
machine by hoisting, the following checks should be
made:
1) Check for removal of all bolts fastening the
part to the relative parts.
2) Check for existence of another part causing
interface with the part to be removed.
WIRE ROPES
1) Use adequate ropes depending on the weight of
parts to be hoisted, referring to the table below:
Wire ropes
(Standard "Z" or "S" twist ropes without galvanizing
Rope diameter (mm) Allowable load (tons)
10.0 1.0
11.2 1.4
12.5 1.6
14.0 2.2
16.0 2.8
18.0 3.6
20.0 4.4
22.4 5.6
30.0 10.0
40.0 18.0
50.0 28.0
60.0 40.0
The allowable load value is estimated to be 1/6 or
1/7 of the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the
hook. Slinging near the edge of the hook may
cause the rope to slip off the hook during
hoisting, and a serious accident can result.
Hooks have maximum strength at the middle
portion.
3) Do not sling a heavy load with one rope alone, but
sling with two or more ropes symmetrically wound
on to the load.
Slinging with one rope may cause turning of
the load during hoisting, untwisting of the rope,
or slipping of the rope from its original winding
position on the load, which can result in a dangerous
accident.
4) Do not sling a heavy load with ropes forming a wide
hanging angle from the hook. When hoisting a load
with two or more ropes, the force subjected to each
rope will increase with the hanging angles. The
table below shows the variation of allowable load
(kg) when hoisting is made with two ropes, each of
which is allowed to sling up to 1000 kg vertically, at
various hanging angles. When two ropes sling a
load vertically, up to 2000 kg of total weight can be
suspended. This weight becomes 1000 kg when
two ropes make a 120E hanging angle. On the
other hand, two ropes are subject to an excessive
force as large as 4000 kg if they sling a 2000 kg
load at a lifting angle of 150E.

DISASSEMBLY AND ASSEMBLY STARTING MOTOR
30-11 Î
STARTING MOTOR
WARNING! Stop the machine on level ground and install
the safety bar on the frame. Lower the bucket to the
ground and stop the engine. Then apply the parking
brake and put blocks under the wheels to prevent the
machine from moving.
WARNING! Disconnect the cable from the negative (-)
terminal of the battery.
REMOVAL
1. Disconnect negative (-) terminal (1) of the battery located
behind the radiator grille.
2. Open engine hood side cover and lock in position.
3. Remove washer tank and bracket (2) and two mounting bolts
with nuts (3) from frame and position out of way.
4. Disconnect cable (4) and harness wires (5) and (6).
5. Remove ground connection (7) with two mounting bolts (8), then
remove starting motor assembly.
INSTALLATION
Ú Install starting motor assembly in reverse order of removal
Mounting bolt: 32 ±4 lbf.ft
(43 ±6 Nm)
(4.38 ±0.61 kgm)

DISASSEMBLY AND ASSEMBLY ALTERNATOR
30-12 Î
ALTERNATOR
REMOVAL
2. Open engine hood side cover and lock in position.
3. Remove 5 mounting bolts of left fan guard half (2) and rotate
down out of way.
4. Install 3/8" drive breaker bar (3) in belt tensioner. Lift up on
breaker bar and remove belt (4) from alternator pulley.
5. Remove output (5) and ground (6) leads from back of
alternator.
6. Remove bottom mounting bolt (7). Supporting the alternator,
remove top mounting bolt (8) and remove the alternator from
the machine.
INSTALLATION
Ú Install starting motor assembly in reverse order of removal
Mounting bolt: 32 ±4 lbf.ft
(43 ±6 Nm)
(4.38 ±0.61 kgm)

DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
30-13 Î
FUEL INJECTION PUMP
REMOVAL
2. Open engine hood right side cover and lock in position (3).
3. Disconnect the throttle linkage (4).
4. Disconnect the fuel inlet line (filter to pump line) (5).
5. Disconnect the return (6) and drain lines (7).
6. Disconnect the electrical wiring (8).
7. Disconnect the six fuel lines (pump to injectors) (9).
8. Remove the Fuel Injection Pump.
Refer to “ENGINE SHOP MANUAL”.
INSTALLATION
Ú Install fuel injection pump assembly in reverse order of removal

DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
30-14 Î
ENGINE OIL COOLER
REMOVAL
2. Open left gull wing side cover (2) on the engine hood and lock
in position.
3. Drain the engine oil.
Refer to “OPERATIONAL & MAINTENANCE MANUAL”.
4. Remove the alternator.
5. Remove the turbocharger drain line (3).
6. Remove the Oil Filter.
Refer to “OPERATIONAL & MAINTENANCE MANUAL”.
7. Remove the Engine Oil Cooler (4).
INSTALLATION
Ú Install engine oil cooler in reverse order of removal.

DISASSEMBLY AND ASSEMBLY WATER PUMP
30-15 Î
WATER PUMP
terminal (1) of the battery.
REMOVAL
1. Open engine hood left side cover and lock into position.
2. Drain water system (coolant) (2).
Refer to “OPERATION & MAINTENANCE MANUAL”.
3. Remove the Fan Belt from the Alternator and Belt
Tennsioner.
Refer to “ALTERNATOR ASSEMBLY”.
4. Remove the alternator.
Refer to “ALTERNATOR ASSEMBLY”.
5. Remove the Water Pump (3).
INSTALLATION
Ú Install the water pump assembly in reverse order of removal.

DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
30-16 Î
NOZZLE HOLDER
REMOVAL
1. Remove hood.
Refer to “HOOD REMOVAL”.
2. Remove air cleaner (1) and bracket (2).
Refer to “AIR CLEANER”.
3. Remove muffler (3) and mount bracket (4).
Refer to “MUFFLER”.
NOTE: When the muffler bracket is removed, the air
conditioner compressor and mount bracket comes
off with it.
4. Remove turbocharger crossover tube (5) (air intake).
5. Remove nozzel holder (6).
INSTALLATION
Ú Install nozzel holder in reverse order of removal. Refer to
“ENGINE SHOP MANUAL”.

DISASSEMBLY AND ASSEMBLY THERMOSTAT
30-17 Î
THERMOSTAT
REMOVAL
1. Drain water system of coolant (2).
Refer to “OPERATION & MAINTENANCE MANUAL”.
2. Open engine hood, left side.
3. Disconnect screw clamp on thermostat and remove hose
connection (3).
4. Remove thermostat.
INSTALLATION
Ú Install thermostat in reverse order of removal. Refer to “ENGINE
SHOP MANUAL”.

DISASSEMBLY AND ASSEMBLY TURBOCHARGER
30-18 Î
TURBOCHARGER
REMOVAL
1. Open engine hood left side cover and lock into position (2).
2. Remove heat shield (3).
3. Disconnect muffler clamp (4), air intake clamp (5), oil drain line
(6) and oil lube line (7).
4. Remove turbocharger.
INSTALLATION
Ú Install turbocharger assembly in reverse order of removal. Refer
to “ENGINE SHOP MANUAL”.

DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
30-19 Î
CYLINDER HEAD
REMOVAL
1. Remove hood.
Refer to “HOOD REMOVAL”.
2. Remove air cleaner (1) and bracket (4).
Refer to “AIR CLEANER”.
3. Remove muffler (3) and mount bracket (2).
Refer to “MUFFLER”.
NOTE: When the muffler bracket is removed, the air
conditioner compressor and mount bracket comes
off with it.
4. Remove turbocharger crossover tube (air intake).
5. Remove cylinder head.
INSTALLATION
Ú Install cylinder head in reverse order of removal. Refer to
“ENGINE SHOP MANUAL”.

DISASSEMBLY AND ASSEMBLY RADIATOR
30-20 Î
RADIATOR
WARNING! Loosen the oil cap slowly to release the
pressure inside the hydraulic tank. Then operate the
control levers several times to release the remaining
pressure in the hydraulic piping.
REMOVAL
1. Engine hood and side covers.
Refer to “REMOVAL OF ENGINE HOOD”.
2. DRAINING COOLANT
Loosen radiator cap (1) to release internal pressure, and open
drain valve (2) and drain coolant from system.
Ú When system is drained close the drain valve.
Ú If the coolant contains antifreeze, dispose of it properly.
Coolant: 35R (9.2 US gals)
3. Fan guards.
A) Remove left fan guard (3) and right fan guard (3A).
Ú Be careful not to damage radiator fins.
4. Rear cover.
A) Remove cover (4) at the bottom rear of the radiator.

30-21 Î
5. Removal of cooling lines.
A) Close petcock (5) to shut off heater hose, remove lower
radiator outlet tube (6) with hoses.
B) Disconnect engine vent line (7), remove radiator inlet tube
(8), and disconnect roading trans cooler line (9) from
thermostat housing.
C) Disconnect torque converter cooler hoses (10) and (11)
from radiator bottom tank.
Ú Radiator fan shroud may have to be disconnected from
radiator and pushed aside to disconnect hoses (10) and
(11).
6. Radiator removal.
A) Disconnect radiator stay rod (12) at radiator, loosen at
frame and rotate forward.

30-22 Î
B) Install lifting eyes (13) and hook up hoist, remove radiator
mounting bolts and rubber mounts (14), and lift radiator
assembly from machine.
Radiator: 110 lbs (50 kg)

30-23 Î
INSTALLATION
Ú Install radiator in reverse order of removal.
Ú Be careful not to damage the fins on the radiator assembly.
Ú Adjust so that the clearance between the shroud and fan is
uniform.
Ú Install so that the clearance between fan and fan guard is
uniform
Ú Temporarily tighten the mounting bolts and fix the position, then
tighten fully.
Ú When installing the radiator, the difference in the clearance
between the fan and radiator on the left and right must be within
3mm (0.118").
Ú Install so that the clearance between the radiator fins and the
front face of the fan is uniform at the top, bottom, left, and right.
Ú The difference between the left and right in the position of the
radiator in the front-to-rear direction must be within 5mm
((0.197").
Ú Tighten hoses without twisting.
Radiator mounting bolts:
82 ±8 lbf.ft
(112.8 ±9.8 Nm)
(11.5 ±1.0 kgm)
Radiator support mounting bolts:
82 ±8 lbf.ft
(112.8 ±9.8 Nm)
(11.5 ±1.0 kgm)
Torque converter cooler hoses:
130 ±22 lbf.ft
(176.4 ±29.4 Nm)
(18.0 ±3.0 kgm)

DISASSEMBLY AND ASSEMBLY ENGINE
30-24 Î
ENGINE
WARNING! Loosen the oil cap slowly to release the
pressure inside the hydraulic tank. Then operate the
control levers several times to release the remaining
pressure in the hydraulic piping.
REMOVAL
1. Engine hood and side covers.
Refer to “REMOVAL OF ENGINE HOOD”.
2. Radiator and piping.
Refer to “REMOVAL OF RADIATOR”.
3. Machines with Air Conditioning.
Ú Note: There are shims (A) and (B) at bottom mounting bolt
between welded spacer and compressor. When removing
keep shims as they were removed.
A) Disconnect wire (1) from harness at top of compressor,
loosen lower mounting bolt (2) and adjusting bolt (3)
allowing for removal of compressor belt (4).
B) Unclip compressor lines (5) at air cleaner, and cut tie straps
(6).
C) Remove hardware (2) and (7), keeping in mind the afore
mentioned shims and position the compressor out of way.

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30-25 Î
4. Right side of engine.
A) Disconnect fuel inlet hose (8) and fuel outlet hose (9) and
remove muffler drain tube (10).
B) Disconnect the fuel cut-off sensor (11), oil pressure switch
(12), and coolant lead (13). Unclamp harness at clamp
(14).
C) Remove slow-blow fuse (15) from mounting bracket (16),
open side door of fuse and disconnect harness lead (17).
Replace screw, close door, and place fuse back in
mounting bracket.
D) At intake manifold, disconnect heat switch cable (18) and
unclamp at air cleaner bracket (19), and remove cable from
frame relay (20).

30-26 Î
E) Unclip engine harness from floor harness (21).
F) Unclip harness and cranking motor cable at throttle bracket
(22) at rear of engine (23), and shut off petcock (24), and
disconnect heater hose (25).
G) Disconnect throttle linkage rod at fuel pump lever (26),
remove throttle bracket (22) and position assembly out of
way.
H) Remove remote engine oil drain bracket (27) from trunnion.

30-27 Î
5. Left side of engine.
A) Disconnect fuel sending unit (28), remove output (29),
ground (30) leads from back of alternator, and water
temperature switch (31).
B) Disconnect harness ground cable (32), remove starter relay
and bracket (33) from engine block.
C) Cut tie straps (34), remove mounting bolts from washer
tank and bracket (35), and position out of way. Disconnect
cranking motor leads (36) and (37).
D) Slide harness connector (38) from flywheel housing bracket
and disconnect and remove engine harness. Disconnect
cranking motor ground cable (39) at frame.

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Komatsu wa180 3 wheel loader service repair manual sna80001 and up