Komatsu WA180-1 WA180-1LC WA180-3 WA180L-3 Wheel Loader & Parallel Tool Carrier Workshop Repair Service Manual PDF - MKMTSWA180LC.zip
Full factory-style service and repair documentation, complete with Electrical Wiring Diagrams, covering the Komatsu Wheel Loader/Parallel Tool Carrier models WA180-1, WA180-1LC, WA180-3 and WA180L-3. Everything a professional technician needs to keep these machines running, troubleshoot faults, and carry out repairs is contained inside.
Inside the Komatsu Wheel Loader/Parallel Tool Carrier WA180-1, WA180-1LC, WA180-3 and WA180L-3 workshop service repair manual you will find:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 3,812 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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MAIN SECTIONS
CEAM001301 - Wheel Loader WA180-3, WA180L-3 Operation & Maintenance Manual...2
INTRODUCTION...5
1. FORWARD...6
2. SAFETY INFORMATION...7
3. INTRODUCTION...8
3.1 INTENDED USE...8
3.2 FEATURES...8
3.3 BREAKING IN A NEW MACHINE...8
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...9
4.1 MACHINE SERIAL NO. PLATE POSITION...9
4.2 ENGINE SERIAL NO. PLATE POSITION...9
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...9
5. CONTENTS...10
SAFETY...15
6. GENERAL PRECAUTIONS...16
7. PRECAUTIONS DURING OPERATION...22
7.1 BEFORE STARTING ENGINE...22
7.2 AFTER STARTING ENGINE...25
7.3 TRANSPORTATION...34
7.4 BATTERY...35
7.5 TOWING...38
8. PRECAUTIONS FOR MAINTENANCE...39
8.1 BEFORE CARRYING OUT MAINTENANCE...39
8.2 DURING MAINTENANCE...44
8.3 TIRES...49
9. POSITION FOR ATTACHING SAFETY LABELS...51
9.1 POSITION FOR ATTACHING SAFETY LABELS...51
OPERATION...56
10. GENERAL VIEW...57
10.1 GENERAL VIEW OF MACHINE...57
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...58
11. EXPLANATION OF COMPONENTS...60
11.1 METER, LAMPS...60
11.2 SWITCHES...64
11.3 CONTROL LEVERS, PEDAL...70
11.4 CAP WITH LOCK...74
11.4.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK...74
11.5 SAFETY BAR...74
11.6 TOWING PIN...75
11.7 GREASE PUMP CLAMP AND RUBBER RING...75
11.8 BACKUP ALARM...75
11.9 FUSE...76
11.9.1 FUSE CAPACITY AND NAME OF CIRCUIT...76
11.10 SLOW BLOW FUSE...77
11.11 STORAGE PLACE FOR THIS MANUAL...78
11.12 AUXILIARY POWER SOURCE...78
11.12.1 FOR MACHINES EQUIPPED WITH ROPS CAB...78
12. CHECK BEFORE STARTING ENGINE...79
12.1 WALK AROUND CHECK...79
12.2 CHECK BEFORE STARTING...82
12.2.1 CHECK COOLANT LEVEL, ADD COOLANT...82
12.2.2 CHECK FUEL LEVEL, ADD FUEL...82
12.2.3 CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL...83
12.2.4 CHECK AND REFILL OF OIL IN BRAKE OIL TANK...83
12.2.5 CHECK DUST INDICATOR...84
12.2.6 CHECK ELECTRICAL WIRING...84
12.2.7 DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR...85
12.2.8 CHECK EFFECT OF PARKING BRAKE...85
12.2.9 CHECK EFFECT OF WHEEL BRAKES...86
12.2.10 CHECK SOUND OF HORN AND BACKUP ALARM...86
12.2.11 CHECK FLASHING OF LAMPS, CHECK FOR DIRT AND DAMAGE...86
12.2.12 CHECK ENGINE EXHAUST COLOR AND SOUND...86
12.2.13 CHECK OPERATIONS OF GAUGES...86
12.2.14 CHECK PLAY OF STEERING WHEEL, CHECK OPERATION OF STEERING...86
12.2.15 CHECK DIRECTION OF REAR VIEW MIRROR, CHECK FOR DIRT OR DAMAGE...86
12.2.16 CHECK LOCK OF CAB DOOR FOR MACHINES EQUIPPED WITH CAB...86
12.3 ADJUSTMENT BEFORE OPERATION...87
12.3.1 OPERATOR'S SEAT...87
12.3.2 ADJUST SEAT BELT...89
12.3.3 ADJUST REAR VEIW MIRRORS...90
12.4 OPERATIONS AND CHECKS BEFORE STARTING ENGINE...91
12.5 STARTING ENGINE...92
12.5.1 NORMAL STARTING PROCEDURES IN COLD AND WARM CONDITIONS...92
12.5.2 STARTING PROCEDURES AFTER EXTENDED SHUTDOWN OR OIL CHANGE...93
12.5.3 STARTING PROCEDURES AFTER CHANGING FUEL FILTERS...93
12.5.4 STARTING PROCEDURES AFTER RUNNING OUT OF FUEL...93
12.6 OPERATIONS AND CHECKS AFTER STARTING ENGINE...94
12.7 MOVING MACHINE OFF...95
12.8 CHANGING GEAR SPEED...97
12.9 CHANGING DIRECTION...97
12.10 TURNING...98
12.11 STOPPING MACHINE...99
12.12 OPERATION OF WORK EQUIPMENT...100
12.13 WORK POSSIBLE USING WHEEL LOADER...101
12.13.1 DIGGING OPERATIONS WITH ROCK PILES...101
12.13.2 DIGGING OPERATIONS ON LEVEL GROUND...102
12.13.3 LEVELING OPERATION...103
12.13.4 PUSHING OPERATIONS...103
12.13.5 LOAD AND CARRY OPERATIONS...103
12.13.6 LOADING OPERATIONS...104
12.14 PRECAUTIONS FOR OPERATION...105
12.14.1 PERMISSIBLE WATER DEPTH...105
12.14.2 IF WHEEL BRAKE DOES NOT WORK...105
12.14.3 PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES...105
12.14.4 PRECAUTIONS WHEN DRIVING MACHINE...106
12.15 ADJUSTING WORK EQUIPMENT POSTURE...107
12.15.1 ADJUSTING BOOM KICKOUT...107
12.15.2 ADJUSTING BUCKET POSITIONER...108
12.15.3 BUCKET LEVEL INDICATOR...108
12.16 PARKING MACHINE...109
12.17 CHECKS AFTER COMPLETION OF ENGINE OPERATION...110
12.18 STOPPING ENGINE...110
12.19 CHECKS AFTER STOPPING ENGINE...111
12.20 LOCKING...111
REMARKS...111
12.21 HANDLING THE TIRES...112
12.21.1 PRECAUTIONS WHEN HANDLING THE TIRES...112
12.21.2 TIRE PRESSURE...112
13. TRANSPORTATION...114
13.1 LOADING, UNLOADING WORK...114
13.2 PRECAUTION FOR LOADING...115
13.3 PRECAUTION FOR LIFTING UP THE VEHICLE...115
13.3.1 THE LOCATION OF DECALS REFERRING TO LIFTING POSITIONS...116
13.3.2 WEIGHT LIST...116
13.3.3 LIFTING PROCEDURE...117
14. COLD WEATHER OPERATIONS...118
14.1 PRECAUTIONS FOR LOW TEMPERATURE...118
14.1.1 FUEL AND LUBRICANTS...118
14.1.2 COOLANT...118
14.1.3 BATTERY...119
14.2 PRECAUTIONS AFTER COMPLETION OF WORK...120
14.3 AFTER COLD WEATHER...120
15. LONG TERM STORAGE...121
15.1 BEFORE STORAGE...121
15.2 DURING STORAGE...121
15.3 AFTER STORAGE...121
16. TROUBLESHOOTING...122
16.1 WHEN MACHINE RUNS OUT OF FUEL...122
16.2 TOWING THE MACHINE...123
16.2.1 WHEN ENGINE CAN BE USED...125
16.2.2 WHEN ENGINE CANNOT BE USED...125
16.3 IF BATTERY IS DISCHARGED...126
16.3.1 REMOVAL AND INSTALLATION OF BATTERY...126
16.3.2 PRECAUTIONS FOR CHARGING BATTERY...127
16.3.3 STARTING ENGINE WITH BOOSTER CABLE...128
16.4 OTHER TROUBLE...130
16.4.1 ELECTRICAL SYSTEM...130
16.4.2 CHASSIS...131
16.4.3 ENGINE...134
MAINTENANCE...136
17. GUIDES TO MAINTENANCE...137
18. OUTLINES OF SERVICE...140
18.1 OUTLINE OF OIL, FUEL, COOLANT...140
18.1.1 OIL...140
18.1.2 FUEL...140
18.1.3 COOLANT...141
18.1.4 GREASE...142
18.1.5 STORING OIL AND FUEL...142
18.1.6 FILTERS...142
18.2 OUTLINE OF ELECTRIC SYSTEM...143
19. WEAR PARTS LIST...144
20. USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE...145
20.1 ENGINE OIL SPECIFICATIONS...146
20.2 DIESEL FUEL SPECIFICATIONS...147
20.3 COOLANT SPECIFICATIONS...148
21.STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS...154
21.1 INTRODUCTION OF NECESSARY TOOLS...154
21.2 TORQUE LIST...155
22. PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS...157
23. MAINTENANCE SCHEDULE CHART...161
23.1 MAINTENANCE SCHEDULE CHART...161
24.SERVICE PROCEDURES...165
24.1 INITIAL 250 HOURS SERVICE...165
24.1.1 REPLACE FUEL FILTERS EVERY 500 HOURS SERVICE...165
24.1.2 REPLACE TRANSMISSION OIL FILTER ELEMENT EVERY 500 HOURS SERVICE...165
24.1.3 REPLACE HYDRAULIC TANK FILTER ELEMENT EVERY 1000 HOURS SERVICE...165
24.2 WHEN REQUIRED...166
24.2.1 CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT...166
24.2.2 CHECK TRANSMISSION OIL LEVEL, ADD OIL...168
24.2.3 CHECK AXLE OIL LEVEL , ADD OIL...169
24.2.4 CLEAN THE AXLE CASE BREATHER...170
24.2.5 CLEAN RADIATOR FINS...170
24.2.6 REPLACE THE BOLT-ON CUTTING EDGES...171
24.2.7 REPLACE BUCKET TEETH (IF EQUIPPED)...172
24.2.8 CHECK AIR CONDITIONER (IF EQUIPPED)...173
24.2.9 CHECK THE AIR CONDITIONER CONDENSER (IF EQUIPPED)...174
24.2.10 CHECK WINDOW WASHING FLUID...174
24.2.11 ADJUST PARKING BRAKE...175
24.2.12 REPLACE SLOW BLOW FUSE...176
24.2.13 CHECK AIR INTAKE HEATER...176
24.3 CHECK BEFORE STARTING...177
24.4 EVERY 50 HOURS SERVICE...178
24.4.1 CHECK THE TIRE INFLATION PRESSURE...178
24.4.2 DRAIN WATER, SEDIMENT FROM FUEL TANK...178
24.5 EVERY 100 HOURS SERVICE...179
24.5.1 CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL...179
24.5.2 CLEAN ELEMENT IN AIR CONDITIONER FRESH AIR FILTER...180
24.5.3 LUBRICATING...181
24.6 EVERY 250 HOURS SERVICE...182
24.6.1 CHANGE OIL IN ENGINE OIL PAN AND REPLACE ENGINE OIL FILTER...182
24.6.2 CHECK FOR LOOSE WHEEL HUB NUTS. TIGHTEN...183
24.6.3 CLEAN ELEMENT IN AIR CONDITIONER RECIRCULATION FILTER...183
24.6.4 CHECK AIR CONDITIONER COMPRESSOR BELT TENSION, ADJUST...184
24.6.5 CHECK BATTERY ELECTROLYTE LEVEL...185
24.6.6 CHECK AIR INTAKE SYSTEM...185
24.6.7 LUBRICATING...186
24.7 EVERY 500 HOURS SERVICE...187
24.7.1 REPLACE FUEL FILTERS...187
24.7.2 REPLACE TRANSMISSION OIL FILTER ELEMENT...189
24.7.3 LUBRICATE...190
24.8 EVERY 1000 HOURS SERVICE...191
24.8.1 CHANGE OIL IN TRANSMISSION CASE, CLEAN STRAINER...191
24.8.2 CLEAN TRANSMISSION CASE BREATHER...192
24.8.3 LUBRICATE...193
24.8.4 CHANGE OIL IN HYDRAULIC OIL TANK, REPLACE HYDRAULIC FILTER ELEMENT...194
24.8.5 ADJUST ENGINE VALVE LASH CLEARANCE...195
24.8.6 CHECK FAN BELT TENSION...196
24.8.7 CHECK FAN BELT TENSIONER BEARING & FAN HUB BEARING & INSPECT FAN BELT...196
24.9 EVERY 2000 HOURS SERVICE...197
24.9.1 COOLING SYSTEM, REPLACE COOLANT AND FLUSH THE SYSTEM...197
24.9.2 REPLACE HYDRAULIC TANK BREATHER ELEMENT...200
24.9.3 CHANGE AXLE OIL...200
24.9.4 CHECK BRAKE DISC WEAR...201
24.9.5 CHECK ALTERNATOR...201
24.9.6 CHECK STARTER MOTOR...201
24.9.7 CHECK VIBRATION DAMPER...201
24.9.8 REPLACE ELEMENT IN AIR COND. RECIRCULATION AIR FILTER AND FRESH AIR FILTER...201
24.9.9 ADJUST ENGINE VALVE LASH CLEARANCE...202
SPECIFICATIONS...205
25.SPECIFICATIONS...205
OPTIONS, ATTACHMENTS...208
26. AVAILABLE ATTACHMENTS...209
27. HEATER AND AIR CONDITIONING (IF EQUIPPED)...211
27.1 GENERAL LOCATION AND FUNCTION OF CONTROL PANEL...211
27.2 COOL BOX COMPARTMENT...212
28.HANDLING E.C.S.S. (ELECTRONIC CONTROLLED SUSPENSION SYSTEM)...213
28.1 STRUCTURE AND FUNCTION OF E.C.S.S...213
28.2 METHOD OF OPERATING E.C.S.S...214
28.3 PRECAUTIONS WHEN OPERATING E.C.S.S...214
28.4 PRECAUTIONS WHEN HANDLING ACCUMULATOR...215
CEAM002100 - Parallel Tool Carrier WA180-3 Operation & Maintenance Manual...217
INTRODUCTION...220
1. FORWARD...221
2. SAFETY INFORMATION...222
3. INTRODUCTION...223
3.1 INTENDED USE...223
3.2 FEATURES...223
3.3 BREAKING IN A NEW MACHINE...223
4. LOCATION OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...224
4.1 MACHINE SERIAL NO. PLATE POSITION...224
4.2 ENGINE SERIAL NO. PLATE POSITION...224
4.3 TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR...224
5. CONTENTS...225
SAFETY...231
6. GENERAL PRECAUTIONS...232
7. PRECAUTIONS DURING OPERATION...238
7.1 BEFORE STARTING ENGINE...238
7.2 AFTER STARTING ENGINE...241
7.3 TRANSPORTATION...250
7.4 BATTERY...251
7.5 TOWING...254
8. PRECAUTIONS FOR MAINTENANCE...255
8.1 BEFORE CARRYING OUT MAINTENANCE...255
8.2 DURING MAINTENANCE...260
8.3 TIRES...265
9. POSITION FOR ATTACHING SAFETY LABELS...267
9.1 POSITION FOR ATTACHING SAFETY LABELS...267
OPERATION...273
10. GENERAL VIEW...274
10.1 GENERAL VIEW OF MACHINE...274
10.2 GENERAL VIEW OF CONTROLS AND GAUGES...275
11. EXPLANATION OF COMPONENTS...277
11.1 METER, LAMPS...277
11.2 SWITCHES...281
11.3 CONTROL LEVERS, PEDAL...287
11.4 CAP WITH LOCK...291
11.4.1 METHOD OF OPENING AND CLOSING CAP WITH LOCK...291
11.5 SAFETY BAR...291
11.6 TOWING PIN...292
11.7 GREASE PUMP CLAMP AND RUBBER RING...292
11.8 BACKUP ALARM...292
11.9 FUSE...293
11.9.1 FUSE CAPACITY AND NAME OF CIRCUIT...293
11.10 SLOW BLOW FUSE...294
11.11 STORAGE PLACE FOR THIS MANUAL...295