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Komatsu WA30-5 Avance 22005 and up Wheel Loader Shop Manual – PDF DOWNLOAD
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Komatsu WA30-5 Avance 22005 and up Wheel Loader Shop Manual
Book Code: SEBM016503
MACHINE MODEL SERIAL NUMBER
WA30-5 22005 and up
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Description
Komatsu WA30-5 Avance 22005 and up Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA30-5 Avance 22005 and up Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA30-5 Avance
Serial Number: 22005 and up
Book Code: SEBM016503
Language: English
Pages: 410
File Format: Portable Document Format (PDF)
KOMATSU WA30-5 AVANCE 22005 AND UP WHEEL LOADER SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA30-5 Avance 22005 and up Wheel Loader Shop Manual
FOREWORD:
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 chapters; these chapters are further divided into the each main group of components.
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu WA30-5 Avance 22005 and up Wheel Loader Shop Manual
COVER............................................................................................ 1 CONTENTS......................................................................................... 2 01 GENERAL....................................................................................... 25 GENERAL ASSEMBLY DRAWING..................................................................... 26 SPECIFICATIONS............................................................................... 28 WEIGHT TABLE................................................................................. 31 LIST OF LUBRICANT AND WATER.................................................................. 32 10 STRUCTURE AND FUNCTION........................................................................ 34 POWER TRAIN.................................................................................. 35 POWER TRAIN SYSTEM........................................................................... 36 RADIATOR・OIL COOLER.......................................................................... 38 DAMPER COUPLING.............................................................................. 39 HST PIPING................................................................................... 40 HST HYDRAULIC SYSTEM DIAGRAM................................................................. 41 HST HYDRAULIC CIRCUIT DIAGRAM................................................................ 42 MAIN PISTON PUMP............................................................................. 43 HIGH-PRESSURE RELIEF VALVE................................................................... 45 LOW-PRESSURE RELIEF VALVE.................................................................... 47 WORK EQUIPMENT・STEERING PUMP, HST CHARGE PUMP................................................ 48 CHARGE PUMP OIL FILTER....................................................................... 49 SPEED RELATED VALVE (DA VALVE)............................................................... 50 PISTON MOTOR................................................................................. 51 DIRECTIONAL SHUTTLE VALVE.................................................................... 53 SERVO VALVE.................................................................................. 54 INCHING VALVE................................................................................ 55 TRANSFER..................................................................................... 56 HST CONTROL.................................................................................. 57 DRIVE SHAFT.................................................................................. 58 AXLE......................................................................................... 59 DIFFERENTIAL................................................................................. 61 FINAL DRIVE.................................................................................. 64 AXLE MOUNT................................................................................... 66 TIRE・WHEEL................................................................................... 67 CENTER HINGE PIN............................................................................. 68 STEERING PIPING.............................................................................. 69 STEERING COLUMN.............................................................................. 70 PRIORITY VALVE............................................................................... 71 STEERING VALVE (ORBIT-ROLL).................................................................. 75 BRAKE, PARKING BRAKE CONTROL................................................................. 83 BRAKE (ALSO USED AS PARKING BRAKE)........................................................... 84 WORK EQUIPMENT PIPING........................................................................ 85 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM...................................................... 86 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM..................................................... 87 WORK EQUIPMENT LEVER LINKAGE................................................................. 88 HYDRAULIC TANK............................................................................... 89 HYDRAULIC FILTER............................................................................. 90 MAIN CONTROL VALVE........................................................................... 91 WORK EQUIPMENT LINKAGE....................................................................... 98 BUCKET....................................................................................... 99 BUCKET POSITIONER............................................................................100 PROXIMITY SWITCH.............................................................................101 ROPS CANOPY..................................................................................102 CENTRAL PANEL (CLUSTER GAUGE)................................................................103 ENGINE START CIRCUIT.........................................................................104 ENGINE STOP CIRUIT...........................................................................104 PREHEATING CIRCUIT...........................................................................105 PARKING BRAKE CIRCUIT........................................................................106 20 TESTING AND ADJUSTING.........................................................................107 STANDARD VALUE TABLE FOR ENGINE..............................................................108 STANDARD VALUE TABLE FOR CHASSIS.............................................................110 TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...................................115 ADJUSTING VALVE CLEARANCE....................................................................116 MEASURING COMPRESSION PRESSURE...............................................................119 TESTING AND ADJUSTING FUEL INJECTION TIMING..................................................120 BLEEDING AIR FROM FUEL CIRCUIT...............................................................126 TESTING AND ADJUSTING FAN BELT TENSION.......................................................127 TESTING FOR ABNORMALITY IN FUEL LEVEL SENSOR.................................................129 MEASURING ACCELERATOR PEDAL..................................................................130 MEASURING OPERATING EFFORT, TRAVEL OF DIRECTIONAL LEVER......................................132 MEASURING STALL SPEED........................................................................133 MEASURING HST OIL PRESSURE...................................................................134 TESTING AND ADJUSTING STEERING WHEEL.........................................................135 MEASURING OPERATING TIME FOR STEERING WHEEL..................................................136 MEASURING STEERING PRESSURE..................................................................137 TESTING AND ADJUSTING BRAKE PEDAL............................................................138 MEASURING OPERATING EFFORT, TRAVEL OF BRAKE PEDAL............................................140 MEASURING BRAKE PERFORMANCE..................................................................141 MEASURING PARKING BRAKE PERFORMANCE..........................................................142 MEASURING BRAKE DISC WEAR....................................................................143 TESTING AND ADJUSTING INCHING VALVE LINKAGE..................................................144 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER.........................................145 MEASURING TRAVEL OF MAIN CONTROL VALVE SPOOL.................................................147 MEASURING WORK EQUIPMENT PRESSURE............................................................148 TESTING AND ADJUSTING BUCKET POSITIONER......................................................150 TROUBLESHOOTING..............................................................................152 POINTS TO REMEMBER WHEN TROUBLESHOOTING..................................................153 SEQUENCE OF EVENTS IN TROUBLESHOOTING....................................................154 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.........................................155 CHECKS BEFORE TROUBLESHOOTING............................................................163 TROUBLESHOOTING OF ELECTRICAL SYSTEM.....................................................164 E-1 ENGINE DOES NOT START............................................................165 TROUBLESHOOTING OF HYDRAULIC SYSTEM (H MODE).............................................170 TROUBLESHOOTING......................................................................171 CHECKING MACHINE BEFORE TROUBLESHOOTING..............................................171 CHECKING HST BEFORE TROUBLESHOOTING..................................................172 H-1 IMPOSSIBLE TO TRAVEL IN EITHER DIRECTION (FORWARD OR REVERSE)....................174 H-2 IMPOSSIBLE TO TRAVEL IN ONE DIRECTION ONLY (EITHER FORWARD OR REVERSE)...........175 H-3 LACKS SPEED IN BOTH DIRECTIONS (FORWARD AND REVERSE).............................176 H-4 LACKS SPEED IN ONE DIRECTION ONLY (FORWARD OR REVERSE)...........................177 H-5 LACKS DRAWBAR PULL IN BOTH DIRECTIONS (FORWARD AND REVERSE)......................177 H-6 LACKS DRAWBAR PULL IN ONE DIRECTION ONLY (FORWARD OR REVERSE)....................178 H-7 ENGINE SPEED IS HIGH WHEN STARTING IN BOTH DIRECTIONS (FORWARD AND REVERSE)......178 H-8 ENGINE SPEED IS HIGH WHEN STARTING IN ONE DIRECTION ONLY (FORWARD OR REVERSE)....178 30 DISASSEMBLY AND ASSEMBLY......................................................................179 HOW TO READ THIS MANUAL......................................................................180 PRECAUTIONS WHEN CARRYING OUT OPERATION......................................................182 SPECIAL TOOLS LIST...........................................................................184 FUEL INJECTION PUMP..........................................................................185 REMOVAL..................................................................................185 INSTALLATION.............................................................................186 ENGINE.......................................................................................187 REMOVAL AND INSTALLATION.................................................................187 RADIATOR.....................................................................................217 REMOVAL AND INSTALLATION.................................................................217 FUEL TANK....................................................................................226 REMOVAL AND INSTALLATION.................................................................226 MAIN PISTON PUMP.............................................................................227 REMOVAL..................................................................................227 INSTALLATION.............................................................................232 DISASSEMBLY AND ASSEMBLY.................................................................236 PISTON MOTOR.................................................................................242 REMOVAL..................................................................................242 INSTALLATION.............................................................................244 DISASSEMBLY..............................................................................246 ASSEMBLY.................................................................................247 ENGINE AND TRANSFER..........................................................................248 REMOVAL AND INSTALLATION.................................................................248 TRANSFER.....................................................................................276 DISASSEMBLY..............................................................................276 ASSEMBLY.................................................................................279 DRIVE SHAFT..................................................................................283 DISASSEMBLY..............................................................................283 ASSEMBLY.................................................................................284 FRONT AXLE...................................................................................285 REMOVAL..................................................................................285 INSTALLATION.............................................................................286 REAR AXLE....................................................................................287 REMOVAL..................................................................................287 INSTALLATION.............................................................................290 DIFFERENTIALS................................................................................293 DISASSEMBLY..............................................................................293 ASSEMBLY.................................................................................296 AXLE HOUSINGS................................................................................307 DISASSEMBLY..............................................................................307 ASSEMBLY.................................................................................312 CENTER HINGE PIN.............................................................................318 REMOVAL..................................................................................318 INSTALLATION.............................................................................325 STEERING VALVE...............................................................................335 REMOVAL AND INSTALLATION.................................................................335 DISASSEMBLY..............................................................................336 ASSEMBLY.................................................................................339 RELIEF VALVE HOUSING SIDE OF STEERING VALVE..................................................344 DISASSEMBLY..............................................................................344 ASSEMBLY.................................................................................345 STEERING CYLINDER............................................................................346 REMOVAL AND INSTALLATION.................................................................346 PARKING BRAKE................................................................................347 REMOVAL..................................................................................347 INSTALLATION.............................................................................349 HYDRAULIC TANK...............................................................................352 REMOVAL AND INSTALLATION.................................................................352 WORK EQUIPMENT VALVE.........................................................................353 REMOVAL AND INSTALLATION.................................................................353 DUMP CYLINDER................................................................................354 REMOVAL AND INSTALLATION.................................................................354 LIFT CYLINDER................................................................................355 REMOVAL AND INSTALLATION.................................................................355 HYDRAULIC CYLINDER...........................................................................356 DISASSEMBLY..............................................................................356 ASSEMBLY.................................................................................358 WORK EQUIPMENT...............................................................................360 REMOVAL..................................................................................360 INSTALLATION.............................................................................363 COUNTERWEIGHT................................................................................366 REMOVAL AND INSTALLATION.................................................................366 INSTRUMENTS PANEL............................................................................367 REMOVAL AND INSTALLATION.................................................................367 40 MAINTENANCE STANDARD..........................................................................368 TRANSMISSION・ENGINE MOUNT....................................................................369 WORK EQUIPMENT・STEERING PUMP, HST CHARGE PUMP................................................370 TRANSFER.....................................................................................371 HST INCHING VALVE............................................................................373 DRIVE SHAFT..................................................................................374 DIFFERENTIAL (1/2)...........................................................................375 DIFFERENTIAL (2/2)...........................................................................376 FINAL DRIVE..................................................................................378 AXLE MOUNT...................................................................................379 STEERING COLUMN..............................................................................380 PRIORITY VALVE...............................................................................381 STEERING CYLINDER MOUNT......................................................................382 BRAKE........................................................................................383 HYDRAULIC CYLINDER...........................................................................384 CENTER HINGE PIN.............................................................................386 WORK EQUIPMENT LINKAGE.......................................................................387 BUCKET POSITIONER............................................................................389 BUCKET.......................................................................................390 90 OTHERS........................................................................................391 ELECTRICAL CIRCUIT DIAGRAM SERIAL NO. 22005-26000............................................392 ELECTRICAL CIRCUIT DIAGRAM (1/2) SERIAL NO. 26001 AND UP.....................................393 ELECTRICAL CIRCUIT DIAGRAM (2/2) SERIAL NO. 26001 AND UP.....................................394 BACKHOE......................................................................................395 CONTENTS.................................................................................396 GENERAL..................................................................................397 GENERAL ASSEMBLY DRAWING.............................................................397 SPECIFICATIONS.......................................................................398 WEIGHT TABLE.........................................................................400 STRUCTURE AND FUNCTION...................................................................401 VALVE CONTROL........................................................................401 HYDRAULIC CIRCUIT DIAGRAM............................................................402 BACKHOE CONTROL VALVE................................................................403 CHECK VALVE..........................................................................405 WORK EQUIPMENT.......................................................................407 ACTUAL ELECTRICAL WIRING DIAGRAM.....................................................408 ELECTRICAL CIRCUIT DIAGRAM...........................................................409 TESTING AND ADJUSTING....................................................................410 ADJUSTING BACKHOE SWING..............................................................410
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
