Komatsu Avance Loader WA300L-3 Shop Manual SEBM017300 – PDF DOWNLOAD

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Komatsu Avance Loader WA300L-3 Shop Manual SEBM017300 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Avance Loader WA300L-3 Shop Manual SEBM017300 – PDF DOWNLOAD

Language : English
Pages :571
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu Avance Loader WA300L-3 Shop Manual SEBM017300 – PDF DOWNLOAD

COVER 1
CONTENTS 2
01 GENERAL 3
GENERAL ASSEMBLY DRAWING 4
SPECIFICATIONS 5
WEIGHT TABLE 8
LIST OF LUBRICANT AND WATER 9
10 STRUCTURE AND FUNCTION 11
POWER TRAIN 12
POWER TRAIN SYSTEM 13
TORQUE CONVERTER,TRANSMISSION PIPING 15
TORQUE CONVERTER 16
TORQUE CONVERTER OIL FILTER 18
TRANSMISSION 19
TRANSMISSION CONTROL VALVE 30
DRIVE SHAFT 50
AXLE 51
DIFFERENTIAL 53
FINAL DRIVE 57
AXLE MOUNT,CENTER HINGE PIN 58
STEERING PIPING 60
STEERING COLUMN 61
PRIORITY VALVE 62
STEERING VALVE (ORBIT-ROLL) 66
2-WAY RESTRICTOR VALVE 74
BRAKE PIPING 75
BRAKE VALVE 76
BRAKE CHARGER VALVE 81
ACCUMULATOR (FOR BRAKE) 85
BRAKE 86
PARKING BRAKE CONTROL 89
PARKING BRAKE 90
HYDRAULIC PIPING 91
WORK EQUIPMENT LEVER LINKAGE 93
HYDRAULIC TANK 94
MAIN CONTROL VALVE 96
WORK EQUIPMENT LINKAGE109
BUCKET POSITIONER AND BOOM KICK-OUT111
AIR CONDITIONER (OPT)115
CENTRAL PANEL (CLUSTER GAUGE)116
SENSORS117
ENGINE STARTING CIRCUIT120
ENGINE STOP CIRCUIT121
ENGINE STOP SOLENOID122
AUTOMATIC PREHEATING CIRCUIT (QHS CONTROLLER)123
ELECTRIC TRANSMISSION CONTROL127
KICK-DOWN SWITCH130
KICK-DOWN ELECTRICAL CIRCUIT DIAGRAM131
TRANSMISSION CUT-OFF SWITCH135
TRANSMISSION CUT-OFF FUNCTION136
20 TESTING AND ADJUSTING138
STANDARD VALUE TABLE FOR ENGINE139
STANDARD VALUE TABLE FOR CHASSIS140
STANDARD VALUE TABLE FOR ELECTRICAL PARTS146
TABLE OF TOOLS FOR TESTINGS,ADJUSTING,AND TROUBLESHOOTING150
MEASURING ENGINE SPEED152
MEASURING EXHAUST GAS COLOR154
ADJUSTING VALVE CLEARANCE155
MEASURING COMPRESSION PRESSURE157
MEASURING BLOW-BY PRESSURE158
TESTING AND ADJUSTING FUEL INJECTION TIMING159
MEASURING ENGINE OIL PRESSURE160
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION161
TESTING AND ADJUSTING ENGINE STOP SOLENOID LINKAGE162
ADJUSTING ACCELERATOR ACTUATOR CABLE163
TESTING AND ADJUSTING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE164
PROCEDURE FOR MOVING MACHINE WHEN TRANSIMISSION VALVE FAILS168
TESTING AND ADJUSTING STEERING OIL PRESSURE169
BLEEDING AIR FROM STEERING CIRCUIT170
TESTING WHEEL BRAKE PERFORMANCE171
TESTING DROP IN WHEEL BRAKE OIL PRESSURE172
MEASURING WHEEL BRAKE DISC WEAR173
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT174
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE175
MEASURING PARKING BRAKE PERFORMANCE177
TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE178
TESTING WEAR OF PARKING BRAKE DISC179
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE180
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT182
ADJUSTING WORK EQUIPMENT LEVER LINKAGE183
ADJUSTING SAFETY LOCK LEVER185
TESTING AND ADJUSTING OF BUCKET PROXIMITY SWITCH186
TESTING AND ADJUSTING OF BOOM PROXIMITY SWITCH187
TROUBLESHOOTING189
POINTS TO REMEMBER WHEN TROUBLESHOOTING190
SEQUENCE OF EVENTS IN TROUBLESHOOTING191
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE192
CHECKS BEFORE TROUBLESHOOTING200
METHOD OF USING TROUBLESHOOTING CHARTS201
CONNECTOR TYPES AND MOUNTING LOCATIONS209
CONNECTOR PIN ARRANGEMENT DIAGRAM211
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS215
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)223
S-1 STARTING PERFORMANCE IS POOR (STARTNG ALWAYS TAKES TIME)224
S-2 ENGINE DOES NOT START225
(1) ENGINE DOES NOT TURN225
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)226
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)227
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)228
S-4 ENGINE STOPS DURING OPERATIONS229
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)230
S-6 ENGINE LACKS OUTPUT (NO POWER)231
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)232
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)233
S-9 OIL BECOMES CONTAMINATED QUICKLY234
S-10 FUEL CONSUMPTION IS EXCESSIVE235
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN236
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)237
S-13 OIL LEVEL RISES238
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)239
S-15 ABNORMAL NOISE IS MADE 240
S-16 VIBRATION IS EXCESSIVE241
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)242
ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE STARTING,STOP AND PREHEATING SYSTEM243
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM244
E-1 ENGINE DOES NOT START245
a) STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START245
b) ENGINE STOP SOLENOID DOES NOT WORK248
E-2 ENGINE DOES NOT STOP249
E-3 PREHEATING IS NOT CARRIED OUT250
E-4 PREHEATING REMAINS ACTUATED252
E-5 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT TRANSMISSION CUT-OFF WORKS NORMALLY)253
E-6 TRANSMISSION DOES NOT WORK NORMALLY254
a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION (ALWAYS STAYS IN 2ND)256
b) PROBLEM IN H-L CIRCUIT257
c) PROBLEM IN SPEED CIRCUIT258
d) PROBLEM IN 4TH CIRCUIT (DOES NOT ENTER 4TH)259
e) CONTACT IN H-L CIRCUIT260
f) CONTACT IN SPEED CIRCUIT261
g) CONTACT IN 4TH CIRCUIT (ALWAYS STAYS IN 4TH)262
h) PROBLEM IN FORWARD CIRCUIT (REVERSE IS NORMAL)263
i) PROBLEM IN REVERSE CIRCUIT (FORWARD IS NORMAL)265
j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE (DOES NOT TRAVEL FORWARD OR IN REVERSE)267
k) CONTACT IN FORWARD CIRCUIT269
l) CONTACT IN REVERSE CIRCUIT271
m) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE273
E-7 KICK-DOWN SWITCH DOES NOT WORK (THE REGULAR F1 TO F4 SHIFTS NORMALLY)274
E-8 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT HOLD IN POSITION)276
E-9 KICK-DOWN IS NOT CANCELED276
a) NOT CANCELED WHEN F/R LEVER IS OPERATED FROM F TO N OR R276
b) NOT CANCELED WHEN SPEED LEVER IS OPERATED FROM 2 TO OTHER POSITION277
E-10 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND279
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)280
POWER TRAIN281
H-1 MACHINE DOES NOT START281
H-2 TRAVEL SPEED IS SLOW,THRUSTING POWER IS WEAK,LACKS POWER ON SLOPES283
H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR285
H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR286
H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH287
STEERING SYSTEM288
H-6 STEERING WHEEL DOES NOT TURN288
H-7 STEERING IS HEAVY289
H-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK290
BRAKE SYSTEM291
H-9 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR291
H-10 BRAKES ARE NOT RELEASED OR BRAKES DRAG292
WORK EQUIPMENT293
H-11 BOOM DOES NOT RISE293
H-12 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER294
H-13 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT295
H-14 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)295
H-15 EXCESSIVE HYDRAULIC DRIFT OF BOOM295
H-16 BOOM SHAKES DURING OPERATION295
H-17 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE296
H-18 BUCKET DOES NOT TILT BACK297
H-19 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER298
H-20 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION299
H-21 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER299
H-22 EXCESSIVE HYDRAULIC DRIFT OF BUCKET299
H-23 BUCKET SHAKES DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD)300
H-24 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT300
H-25 BOOM,BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY301
30 DISASSEMBLY AND ASSEMBLY302
METHOD OF USING MANUAL304
PRECAUTIONS WHEN CARRYING OUT OPERATION305
SPECIAL TOOL LIST307
SKETCHES OF SPECIAL TOOLS310
STARTING MOTOR312
REMOVAL AND INSTALLATION312
ALTERNATOR313
REMOVAL AND INSTALLATION313
ENGINE OIL COOLER CORE314
REMOVAL AND INSTALLATION314
FUEL INJECTION PUMP315
REMOVAL315
INSTALLATION317
WATER PUMP320
REMOVAL AND INSTALLATION320
TURBOCHARGER321
REMOVAL AND INSTALLATION321
NOZZLE HOLDER322
REMOVAL322
INSTALLATION323
THERMOSTAT324
REMOVAL AND INSTALLATION324
ENGINE HOOD325
REMOVAL325
INSTALLATION326
CYLINDER HEAD327
REMOVAL327
INSTALLATION331
RADIATOR334
REMOVAL334
INSTALLATION335
ENGINE336
REMOVAL336
INSTALLATION339
TORQUE CONVERTER CHARGING PUMP340
REMOVAL AND INSTALLATION340
TORQUE CONVERTER,TRANSMISSION341
REMOVAL341
INSTALLATION344
TORQUE CONVERTER345
DISASSEMBLY345
ASSEMBLY347
TRANSMISSION 349
DISASSEMBLY349
ASSEMBLY359
CLUTCH PACK372
DISASSEMBLY372
ASSEMBLY378
PARKING BRAKE391
DISASSEMBLY391
ASSEMBLY394
TRANSMISSION CONTROL VALVE397
REMOVAL397
INSTALLATION398
DISASSEMBLY399
ASSEMBLY401
DRIVE SHAFT403
DISASSEMBLY403
ASSEMBLY405
FRONT AXLE407
REMOVAL407
INSTALLATION409
REAR AXLE410
REMOVAL410
INSTALLATION414
DIFFERENTIAL415
DISASSEMBLY415
ASSEMBLY419
AXLE HOUSING429
DISASSEMBLY429
ASSEMBLY436
CENTER HINGE PIN445
REMOVAL445
INSTALLATION450
STEERING VALVE454
REMOVAL454
INSTALLATION455
DISASSEMBLY456
ASSEMBLY459
PRIORITY VALVE463
REMOVAL AND INSTALLATION463
STEERING CYLINDER464
REMOVAL AND INSTALLATION464
RIGHT BRAKE VALVE (TANDEM)465
DISASSEMBLY465
ASSEMBLY466
LEFT BRAKE VALVE (SINGLE)467
DISASSEMBLY467
ASSEMBLY468
PARKING BRAKE DISC469
REMOVAL469
INSTALLATION470
HYDRAULIC TANK471
REMOVAL AND INSTALLATION471
HYDRAULIC FILTER472
REMOVAL AND INSTALLATION472
HYDRAULIC COOLER473
REMOVAL AND INSTALLATION473
HYDRAULIC,STEERING PUMP474
REMOVAL AND INSTALLATION474
MAIN CONTROL VALVE475
REMOVAL475
INSTALLATION476
DISASSEMBLY477
ASSEMBLY479
BUCKET CYLINDER481
REMOVAL481
INSTALLATION482
BOOM CYLINDER483
REMOVAL483
INSTALLATION484
HYDRAULIC CYLINDER485
DISASSEMBLY485
ASSEMBLY488
WORK EQUIPMENT492
REMOVAL492
INSTALLATION495
COUNTERWEIGHT498
REMOVAL AND INSTALLATION498
FUEL TANK499
REMOVAL499
INSTALLATION500
CAB501
REMOVAL501
INSTALLATION502
FLOOR FRAME503
REMOVAL503
INSTALLATION505
ACCUMULATOR CHARGE VALVE506
REMOVAL AND INSTALLATION506
ACCUMULATOR UNIT507
REMOVAL AND INSTALLATION507
AIR CONDITIONER UNIT508
REMOVAL508
INSTALLATION513
AIR CONDITIONER CONDENSER514
REMOVAL514
INSTALLATION515
DRY RECEIVER516
REMOVAL AND INSTALLATION516
AIR CONDITIONER COMPRESSOR517
REMOVAL517
INSTALLATION518
MONITOR PANEL519
REMOVAL AND INSTALLATION519
40 MAINTENANCE STANDARD520
ENGINE MOUNT,TRANSMISSION MOUNT521
TORQUE CONVERTER CHARGING PUMP522
TORQUE CONVERTER523
TRANSMISSION524
TRANSMISSION CONTROL VALVE532
DRIVE SHAFT536
DIFFERENTIAL (1/2)537
DIFFERENTIAL (2/2)538
FINAL DRIVE540
AXLE MOUNT542
CENTER HINGE PIN543
STEERING COLUMN545
PRIORITY VALVE546
STEERING CYLINDER MOUNT547
BRAKE548
BRAKE VALVE549
PARKING BRAKE552
HYDRAULIC PUMP (STEERING,HYDRAULIC,BRAKE CHARGE PUMP)553
MAIN CONTROL VALVE554
HYDRAULIC CYLINDER558
WORK EQUIPMENT LINKAGE559
BUCKET561
BUCKET POSITIONER AND BOOM KICK-OUT562
90 OTHERS563
TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM564
BRAKE HYDRAULIC CIRCUIT DIAGRAM565
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM567
ELECTRIC CIRCUIT DIAGRAM (1/3)569
ELECTRIC CIRCUIT DIAGRAM (2/3)570
ELECTRIC CIRCUIT DIAGRAM (3/3)571

IMAGES PREVIEW OF THE MANUAL:

S.M 15/12/24