Komatsu WA180-3 Avance Wheel Loader 1998–2008 Shop Manual Set (P/N SEBM005804)

The main volume separates the earlier and later engine configurations, while the EU volume documents its emergency-steering and auto-shift equipment. Matching the machine's serial range and installed systems helps you select the appropriate tests and circuit diagrams.

Engine repair scope: Both volumes provide machine-level engine tests and selected removal and installation procedures. Full internal engine details require the separate Komatsu 95 Series and 102 Series Engine Shop Manuals, which are not included.

PDF Navigation and File Contents

Bookmarks and wiring detail: Both PDFs have embedded bookmarks for chapters and individual procedures. PDF text search is not available. Small wiring labels require zooming; the EU volume's enlarged main electrical circuits are in the final Others section.

The ZIP download contains two printable English PDFs totaling 1,155 pages, including all covers and preliminary pages, the main volume's three revision-list pages, and the EU volume's three-page Others section.

Power Train Repair, Hydraulic Tests and Electrical Diagnosis

The following selected contents show the range of workshop material. Further topics include proximity-switch operation and instrument-panel removal and installation.

• Engine testing and related repairs: Valve-clearance adjustment, compression and injection-timing checks, plus engine and engine-component removal and installation.

• Transmission and torque converter: Internal overhaul, clutch-pack disassembly and assembly, control-valve service, stall testing and transmission oil-pressure checks.

• Axles and articulation: Axle removal, differential and axle-housing overhaul, planetary final-drive inspection, drive-shaft repair and center-hinge work.

• Steering and brakes: Orbit-roll steering-valve service, priority-valve removal, brake-booster and wet-disc brake repair, bleeding and parking-brake adjustment.

• Work-equipment hydraulics: Combined hydraulic/steering pump and main control valve removal, cylinder repair, hydraulic pressure and drift tests, bucket-positioner and boom-kick-out adjustment.

• Electrical and EU systems: Wiring and hydraulic schematics, auto-shift controller failure-code diagnosis, cut-off and neutralizer circuits, E.C.S.S. and emergency-steering documentation.

Prepared for service-workshop personnel, these manuals assume access to the specified test equipment, special tools and lifting equipment.

Engine, Fuel and Cooling Work

Engine diagnosis covers starting problems, low output, exhaust smoke, oil consumption, overheating and abnormal noise. The main volume separates the S6D95L-series and S6D102E-series troubleshooting charts by machine serial range.

Related procedures cover fuel injection pump and nozzle holder removal and installation, cylinder-head removal and installation, and turbocharger replacement. Cooling work includes the water pump, thermostat, radiator and engine oil cooler, with a separate radiator/hydraulic-cooler procedure for later machines.

Transmission, Differential and Axle Overhaul

Step-by-step clutch-pack procedures include operating checks. Functional descriptions explain the modulation fill valve and directional/speed-clutch operation, alongside repair sections for the control, solenoid and accumulator valves.

Repair checks: Stall-speed and oil-pressure testing accompany power-train fault charts for weak travel, shift shock, engagement delay and overheating. The main volume distinguishes transmission hydraulic diagrams and inspection standards by transmission serial number.

Differential work includes bevel-gear tooth-contact, backlash and bearing-preload adjustments. Axle-housing procedures cover the planetary final drives and axle-shaft end play; Maintenance Standard supplies the related inspection limits.

Assembly cautions: The clutch-pack instructions address seal shaping because installing unshaped piston seals can damage them. Differential shim movement must preserve total shim thickness to retain bearing preload.

Steering, Brakes and Loader Hydraulics

Steering coverage explains the column, priority and cushion valves, with orbit-roll valve disassembly and assembly. The EU volume adds the ground-driven emergency steering pump, security and diverter valves, circuit-operation drawings and component inspection standards.

Brake testing includes pedal linkage, braking performance, oil-pressure retention and disc wear. The steering-valve assembly section identifies the rotor/drive-shaft relationship that determines valve timing; the differential chapter warns that hammering in the brake piston can damage the piston and O-rings.

Cylinder repair includes piston rings, rod packing, bushings and dust seals, followed by post-repair air-bleeding guidance. Tank and work-equipment linkage diagrams accompany lever-force, spool-travel and cycle-time checks.

Electrical Circuits and Auto-Shift Troubleshooting

Circuit-tracing material includes the Transmission Hydraulic System Diagram, Transmission Hydraulic Circuit Diagram, Work Equipment Hydraulic Circuit Diagram, Electrical Wiring Diagram, Air Conditioner Electrical Circuit Diagram and EU emergency-steering circuit.

The EU auto-shift diagnostics include failure codes and checks for forward/reverse, high/low and speed solenoids; directional and gear-shift lever signals; and travel-speed and engine-speed inputs. Separate checks address kick-down, transmission cut-off, the neutralizer relay, buzzer and controller power.

The main volume explains the travel damper system; the EU volume presents the Electrically Controlled Suspension System (E.C.S.S.) with hydraulic/electrical circuits and operating tables. Component section views support the torque converter, transmission control valve, priority valve, brake booster and main control valve.

Workshop Tools and Inspection References

Tool tables identify the 799-203-9000 multi-tachometer kit, 799-101-5002 hydraulic tester and 799-601-7400 T-adapter kit. Overhaul equipment includes the 793-310-1300 transmission-clutch stand, 793-510-1600 differential mandrel and 793-605-1001 brake tester.

Reference material includes tightening tables for metric fasteners, flared nuts, split-flange bolts, O-ring boss joints and plugs. Fluid capacities, lubricant selection by ambient temperature and component weights accompany clearance and wear standards for mounts, the center hinge, brakes, pump, cylinders, linkage, bucket, positioner and kick-out mechanism.

For raised-loader work, frame separation, hydraulic or brake service, and heavy assembly handling, follow the manual's machine-support and isolation precautions.

A Preview of Serial-Specific Valve-Clearance Data

For the main volume's S6D95L-1, serial 50001–52999, the cold valve-clearance table lists 0.35 mm for intake valves and 0.50 mm for exhaust valves.

For the S6D102E-1-1A, serial 53001 and up, the corresponding cold values are 0.25 mm intake and 0.51 mm exhaust. The Testing and Adjusting section provides the associated adjustment procedures.