A WA180-3 that drags a clutch pack mid-cycle is headed for a transmission split, and the Komatsu WA180-3 shop manual PDF (SEBM005802, 549 pages) walks you through that wheel loader from General specifications to Maintenance Standard. Hydraulic schematics trace oil from the pump through the main control valve to the lift arm and bucket cylinders, and wiring diagrams map the circuits behind the transmission control valve and the 24 V, 5.5 kW starting motor. Disassembly and Assembly takes up the largest share of the book (engine, transmission, clutch packs), while Testing and Adjusting pairs troubleshooting charts with standard value tables for engine and chassis. Check the alternator against its 24 V, 35 A rating before you condemn the batteries, and bring a No. 04 hose nut to 78.5 ± 19.6 Nm. Nobody wants to split a loader twice for one clutch pack. Bookmarked and text searchable, the PDF travels to wherever your loader is parked.
What's Inside This Komatsu WA180-3 Manual
| System | Pages | Key Topics |
|---|---|---|
| General | 1-31 | Safety, Specifications |
| Structure and Function | 32-175 | Power Train System, Transmission Control Valve, Main Control Valve |
| Testing and Adjusting | 176-277 | Standard Value Table for Engine, Standard Value Table for Chassis |
| Disassembly and Assembly | 278-495 | Engine, Transmission, Clutch Pack |
| Maintenance Standard | 496-549 | Transmission, Differential |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Tightening torque of hose nuts (Nominal No. 02) | 24.5 ± 4.9 Nm | p. 15 |
| Tightening torque of hose nuts (Nominal No. 03) | 49 ± 19.6 Nm | p. 15 |
| Starting motor | 24 V 5.5 kW | p. 27 |
| Alternator | 24 V 35 A | p. 27 |
| Filter mesh size | 10 microns | p. 43 |
| Filtering area | 8900 cm2 | p. 43 |
| Bypass valve set pressure | 0.15 MPa (1.5 kg/cm²) | p. 118 |
| Check valve set pressure | 0.024 MPa (0.24 kg/cm²) | p. 118 |
| Torque converter outlet port pressure | 0.38 ± 0.05 MPa (3.9 ± 0.5 kg/cm²) | p. 178 |
| Standard length of modulating time adjustment screw | 6.75 mm | p. 202 |
| Coolant capacity | 20 L | p. 302 |
| Radiator mounting bolt torque | 112.8 ± 9.8 Nm | p. 305 |
Komatsu WA180-3 Common Problems This Manual Covers
Komatsu WA180-3 wheel loader engine overheating and cooling water level low after a loading shift
Check the cooling water level with the engine cold, then run the overheating checks in the engine troubleshooting section. Refill to the 20 L cooling system capacity listed on page 302. If the radiator was removed, torque the radiator and radiator support mounting bolts to 112.8 ± 9.8 Nm per page 305.
Manual Section: Engine System TroubleshootingEngine starting performance poor, cranks but is slow to start or will not start
Test both batteries first; the machine runs two 12 V 110 Ah units for its 24 V system per page 27. Verify the 24 V 5.5 kW starting motor gets full voltage while cranking and the 24 V 35 A alternator charges after start. Then follow the starting checks in the engine troubleshooting section.
Manual Section: Engine System TroubleshootingEngine oil pressure reading low and oil consumption high between scheduled service intervals
Check the engine oil level on flat ground with the engine stopped; the oil pan holds 12.5 L specified per page 30. Inspect the drained oil for contamination, then work through the oil pressure and oil consumption checks in the engine troubleshooting section before pulling anything apart.
Manual Section: Engine System TroubleshootingMachine travel speed slow and thrusting power weak when pushing into a pile
Check transmission oil level first; the transmission case takes 28.0 L specified per page 30. Then tee a gauge into the torque converter outlet port and measure pressure against 0.38 ± 0.05 MPa (3.9 ± 0.5 kg/cm²) per page 178. Watch torque converter oil temperature during the test as well.
Manual Section: Testing and Adjusting p. 178Transmission shock during shifting and noticeable time lag before the clutch engages
Adjust the modulating time adjustment screw: back it out fully, then screw it in 4 1/2 turns to the 6.75 mm standard length given on page 202. If the shock persists, inspect the clutch accumulator springs against the installed loads on page 517: forward clutch 158 N (16.1 kg), 1st clutch 78.8 N (8.04 kg).
Manual Section: Testing and Adjusting p. 202Boom lifting power weak and hydraulic drift on the boom with the control lever in neutral
Check hydraulic oil level first; the hydraulic system takes 80 L specified per page 30. Raise the boom, set the control lever in neutral and watch for drift, then run the boom lifting power and hydraulic drift checks in the work equipment troubleshooting before opening the main control valve.
Manual Section: Work Equipment TroubleshootingFrequently Asked Questions
How do I bleed air from the fuel system on the WA180-3?
To bleed the fuel system, turn the starting switch to the START position and crank the engine 2 or 3 times for 15 to 20 seconds each. The air will pass through the overflow valve (1) and be automatically released into the fuel tank. p. 164
How do I bleed air from the brake system?
Depress the brake pedal, loosen the bleeder screw to bleed the air, then tighten the screw while keeping the pedal depressed. Repeat this until no more bubbles come out, ensuring the brake oil tank remains full throughout the process. p. 214
What is the standard torque for the cylinder head mounting bolts on the Komatsu WA180-3?
The cylinder head mounting bolts are tightened in three steps: first to 68.6 ± 9.8 Nm (7 ± 1 kgm), second to 107.9 ± 4.9 Nm (11.0 ± 0.5 kgm), and third to 90° +30°/-0°. p. 298
What is the standard valve clearance for the intake and exhaust valves on the Komatsu WA180-3?
The standard valve clearance for the intake valve is 0.35 mm and for the exhaust valve is 0.50 mm when the engine is cold. p. 177
What is the capacity of the transmission oil system on the Komatsu WA180-3?
The specified capacity for the transmission case is 28.0 liters, with a refill capacity of 23.5 liters. p. 30
What format is this Komatsu WA180-3 manual in?
Straight to your device: 549 pages of searchable Shop Manual, downloadable the moment payment goes through.
Is this Komatsu WA180-3 manual print-friendly?
Yes. Print a single page or a chapter for your own shop use, on letter or A4.
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