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Komatsu WA300-1, WA320-1 Wheel Loader Shop Manual 10001 and up – PDF DOWNLOAD
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Komatsu WA300-1, WA320-1 Wheel Loader Shop Manual
MACHINE MODEL SERIAL No.
- WA300-1 10001 and up
- WA320-1 10001 and up
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Description
Komatsu WA300-1, WA320-1 Wheel Loader Shop Manual 10001 and up
FILE DETAILS:
Komatsu WA300-1, WA320-1 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA300-1, WA320-1
Serial Number: 10001 and up
Book Code: SEBM04190107
Language: English
Pages: 841
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA300-1, WA320-1 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.
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” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu WA300-1, WA320-1 Wheel Loader Shop Manual
COVER............................................................................................................................................. 1 CONTENTS.......................................................................................................................................... 2 01 GENERAL........................................................................................................................................ 38 GENERAL VIEW.................................................................................................................................. 39 GENERAL ASSEMBLY DRAWING...................................................................................................................... 40 SPECIFICATIONS................................................................................................................................ 41 ENGINE ASSEMBLY DRAWING....................................................................................................................... 43 ENGINE SPECIFICATIONS......................................................................................................................... 44 WEIGHT TABLE.................................................................................................................................. 45 TABLE OF OIL AND COOLANT QUANTITIES........................................................................................................... 46 LOCATION OF SERIAL NUMBERS.................................................................................................................... 47 10 ENGINE......................................................................................................................................... 48 11 STRUCTURE AND FUNCTION..................................................................................................................... 48 ENGINE AND TRANSMISSION MOUNT............................................................................................................. 49 RADIATOR AND COOLER....................................................................................................................... 50 FUEL TANK AND PIPING...................................................................................................................... 51 ENGINE CONTROL............................................................................................................................ 52 12 TESTING AND ADJUSTING...................................................................................................................... 53 TABLE OF JUDGEMENT STANDARD............................................................................................................... 54 TESTING AND ADJUSTING TOOL LIST........................................................................................................... 55 ADJUSTING VALVE CLEARANCE................................................................................................................. 56 MEASURING COMPRESSION PRESSURE............................................................................................................ 57 TESTING AND ADJUSTING FUEL INJECTION TIMING............................................................................................... 58 MEASURING ENGINE OIL PRESSURE AND TEMPERATURE............................................................................................. 60 MEASURING BLOW-BY PRESSURE................................................................................................................ 61 TESTING AND ADJUSTING FAN BELT TENSION.................................................................................................... 62 MEASURING EXHAUST GAS COLOR............................................................................................................... 63 MEASURING OPERATING FORCE AND OPERATING ANGLE OF ACCELERATOR PEDAL........................................................................ 64 MEASURING ACCELERATOR PEDAL............................................................................................................... 66 ADJUSTING FUEL CUT SOLENOID............................................................................................................... 68 13 DISASSEMBLY AND ASSEMBLY................................................................................................................... 69 STARTING MOTOR ASSEMBLY................................................................................................................... 70 REMOVAL............................................................................................................................... 70 INSTALLATION.......................................................................................................................... 70 ALTERNATOR ASSEMBLY....................................................................................................................... 71 REMOVAL............................................................................................................................... 71 INSTALLATION.......................................................................................................................... 71 ENGINE OIL COOLER ASSEMBLY................................................................................................................ 72 REMOVAL............................................................................................................................... 72 INSTALLATION.......................................................................................................................... 72 FUEL INJECTION PUMP ASSEMBLY.............................................................................................................. 73 REMOVAL............................................................................................................................... 73 INSTALLATION.......................................................................................................................... 73 WATER PUMP ASSEMBLY....................................................................................................................... 74 REMOVAL............................................................................................................................... 74 INSTALLATION.......................................................................................................................... 74 NOZZLE HOLDER ASSEMBLY.................................................................................................................... 75 REMOVAL............................................................................................................................... 75 INSTALLATION.......................................................................................................................... 75 TURBOCHARGER ASSEMBLY..................................................................................................................... 76 REMOVAL............................................................................................................................... 76 INSTALLATION.......................................................................................................................... 76 CYLINDER HEAD ASSEMBLY.................................................................................................................... 77 REMOVAL............................................................................................................................... 77 INSTALLATION.......................................................................................................................... 83 RADIATOR.................................................................................................................................. 91 REMOVAL............................................................................................................................... 91 INSTALLATION.......................................................................................................................... 93 ENGINE.................................................................................................................................... 95 REMOVAL............................................................................................................................... 95 INSTALLATION..........................................................................................................................101 FUEL TANK ASSEMBLY........................................................................................................................106 REMOVAL...............................................................................................................................106 INSTALLATION..........................................................................................................................107 20 POWER TRAIN....................................................................................................................................108 21 STRUCTURE AND FUNCTION.....................................................................................................................108 GENERAL...................................................................................................................................109 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN.................................................................................................111 POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS..................................................................................................113 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................114 TORQUE CONVERTER AND TRANSMISSION PIPING..................................................................................................115 TORQUE CONVERTER CHARGING PUMP............................................................................................................116 TORQUE CONVERTER..........................................................................................................................117 TORQUE CONVERTER OIL FILTER...............................................................................................................119 TORQUE CONVERTER OIL COOLER...............................................................................................................120 TORQUE CONVERTER REGULATOR VALVE..........................................................................................................121 TORQFLOW TRANSMISSION.....................................................................................................................123 CLUTCH PACK...........................................................................................................................127 TRANSMISSION CONTROL VALVE (SERIAL NO. 10001-19999).......................................................................................137 UPPER VALVE...........................................................................................................................139 LOWER VALVE...........................................................................................................................140 PILOT REDUCING VALVE..................................................................................................................141 TRANSMISSION SOLENOID VALVE...........................................................................................................142 PRIORITY RELIEF VALVE.................................................................................................................143 MODULATING RELIEF VALVE...............................................................................................................144 MODULATING RELIEF VALVE, ACCUMULATOR VALVE, QUICK RETURN VALVE........................................................................145 EMERGENCY MANUAL SPOOL................................................................................................................149 SPEED SPOOL...........................................................................................................................152 TRANSMISSION CONTROL VALVE (SERIAL NO. 20001 AND UP)......................................................................................153 TRANSMISSION SOLENOID VALVE...........................................................................................................154 UPPER VALVE...........................................................................................................................155 LOWER VALVE...........................................................................................................................156 TORQUE CONVERTER OIL OUTLET VALVE.....................................................................................................157 PILOT REDUCING VALVE..................................................................................................................158 TRANSMISSION SOLENOID VALVE...........................................................................................................159 PRIORITY AND MAIN REGULATOR VALVE.....................................................................................................160 MAIN REGULATOR VALVE..................................................................................................................161 MODULATING RELIEF VALVE, ACCUMULATOR VALVE, QUICK RETURN VALVE........................................................................162 EMERGENCY MANUAL SPOOL................................................................................................................166 DIRECTIONAL SPOOL.....................................................................................................................168 FILL VALVE............................................................................................................................169 PILOT OIL FILTER......................................................................................................................171 DIFFERENTIAL..............................................................................................................................173 FINAL DRIVE...............................................................................................................................177 AXLE MOUNT................................................................................................................................179 TIRE AND WHEEL............................................................................................................................183 22 TESTING AND ADJUSTING......................................................................................................................184 STANDARD VALUE TABLE......................................................................................................................185 TOOL LIST FOR TESTING AND ADJUSTING.......................................................................................................186 MEASURING ENGINE STALL SPEED..............................................................................................................187 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION...............................................................................189 MEASURING SHIFT LEVER.....................................................................................................................193 TIRE AND WHEEL............................................................................................................................194 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL............................................................................................195 TROUBLESHOOTING ..........................................................................................................................196 PRECAUTIONS WHEN TROUBLESHOOTING......................................................................................................197 METHOD OF READING TROUBLESHOOTING TABLE...............................................................................................199 PREVENTING RECURRENCE OF TROUBLE......................................................................................................201 METHOD OF LOCATING MAIN PROBLEM POINTS WHEN TROUBLESHOOTING TRANSMISSION SYSTEM.......................................................202 TROUBLESHOOTING TABLE.................................................................................................................203 1. MACHINE DOES NOT MOVE OFF......................................................................................................203 2. MACHINE SPEED IS LOW, THRUST IS WEAK, GRADEABILITY FALLS OFF...................................................................205 4. LARGE TIME LAG WHEN MOVING OFF OR CHANGING GEAR................................................................................206 5. OIL TEMPERATURE IN TORQUE CONVERTER IS HIGH....................................................................................207 23 DISASSEMBLY AND ASSEMBLY...................................................................................................................208 TORQUE CONVERTER CHARGING PUMP............................................................................................................209 REMOVAL...............................................................................................................................209 INSTALLATION..........................................................................................................................209 TRANSMISSION, TORQUE CONVERTER............................................................................................................210 REMOVAL...............................................................................................................................210 INSTALLATION..........................................................................................................................217 TORQUE CONVERTER..........................................................................................................................223 DISASSEMBLY...........................................................................................................................223 ASSEMBLY..............................................................................................................................226 TRANSMISSION..............................................................................................................................229 DISASSEMBLY...........................................................................................................................229 ASSEMBLY..............................................................................................................................238 CLUTCH PACK...............................................................................................................................251 DISASSEMBLY...........................................................................................................................251 ASSEMBLY..............................................................................................................................259 TRANSMISSION CONTROL VALVE................................................................................................................274 REMOVAL...............................................................................................................................274 INSTALLATION..........................................................................................................................275 DISASSEMBLY...........................................................................................................................277 ASSEMBLY..............................................................................................................................279 DRIVE SHAFT...............................................................................................................................286 DISASSEMBLY...........................................................................................................................286 ASSEMBLY..............................................................................................................................288 FRONT AXLE................................................................................................................................290 REMOVAL...............................................................................................................................290 INSTALLATION..........................................................................................................................292 REAR AXLE.................................................................................................................................294 REMOVAL...............................................................................................................................294 INSTALLATION..........................................................................................................................297 DIFFERENTIAL..............................................................................................................................300 DISASSEMBLY...........................................................................................................................300 ASSEMBLY..............................................................................................................................304 AXLE HOUSING..............................................................................................................................315 DISASSEMBLY...........................................................................................................................315 ASSEMBLY..............................................................................................................................319 24 MAINTENANCE STANDARD.......................................................................................................................325 ENGINE AND TRANSMISSION MOUNT.............................................................................................................326 TORQUE CONVERTER CHARGING PUMP............................................................................................................327 TORQUE CONVERTER..........................................................................................................................328 TORQUE CONVERTER REGULATOR VALVE..........................................................................................................329 TRANSMISSION..............................................................................................................................330 TRANSMISSION CLUTCH ASSEMBLY..............................................................................................................333 TRANSMISSION CONTROL VALVE................................................................................................................335 UPPER VALVE...........................................................................................................................335 LOWER VALVE...........................................................................................................................341 SOLENOID VALVE............................................................................................................................343 AXLE......................................................................................................................................345 DIFFERENTIAL..............................................................................................................................347 FINAL DRIVE...............................................................................................................................349 DRIVE SHAFT...............................................................................................................................350 AXLE MOUNT................................................................................................................................351 40 STEERING SYSTEM................................................................................................................................354 41 STRUCTURE AND FUNCTION.....................................................................................................................354 GENERAL...................................................................................................................................355 HYDRAULIC CIRCUIT FOR STEERING............................................................................................................357 HYDRAULIC CIRCUIT DIAGRAM FOR STEERING................................................................................................358 OPERATION OF STEERING VALVE...........................................................................................................359 STEERING VALVE............................................................................................................................361 STEERING RELIEF VALVE.................................................................................................................363 SAFETY VALVE (WITH SUCTION VALVE).....................................................................................................364 OPERATION OF DEMAND VALVE.............................................................................................................366 TWO-WAY RESTRICTOR VALVE..............................................................................................................368 STEERING COLUMN AND GEAR BOX..............................................................................................................369 STEERING LINKAGE..........................................................................................................................370 STEERING CYLINDER.........................................................................................................................371 CENTER HINGE PIN..........................................................................................................................372 EMERGENCY STEERING PUMP (IF EQUIPPED).....................................................................................................373 DIVERTER VALVE (IF EQUIPPED)..............................................................................................................374 SECURITY VALVE (IF EQUIPPED)..............................................................................................................377 42 TESTING AND ADJUSTING......................................................................................................................380 STANDARD VALUE TABLE......................................................................................................................381 TOOL LIST FOR TESTING AND ADJUSTING.......................................................................................................381 MEASURING STEERING WHEEL PLAY.............................................................................................................382 MEASURING OPERATING FORCE OF STEERING WHEEL...............................................................................................383 OPERATING TIME OF STEERING WHEEL LOCK TO LOCK.............................................................................................384 TESTING STEERING LINKAGE..................................................................................................................385 ADJUSTING STEERING LINKAGE................................................................................................................386 STEERING OIL PRESSURE.....................................................................................................................387 TROUBLESHOOTING...........................................................................................................................388 TROUBLESHOOTING TABLE.................................................................................................................389 1. STEERING WHEEL DOES NOT TURN...................................................................................................389 2. STEERING WHEEL IS SLUGGISH.....................................................................................................390 3. STEERING WHEEL MOVES UNSTEADILY OR IS SUBJECTED TO LARGE SHOCK.................................................................391 4. MACHINE TENDS TO TURN NATURALLY IN ONE PARTICULAR DIRECTION WHEN TRAVELING.....................................................391 5. LEFT AND RIGHT TURNING RADII ARE DIFFERENT.....................................................................................391 43 DISASSEMBLY AND ASSEMBLY...................................................................................................................392 STEERING GEAR BOX.........................................................................................................................393 REMOVAL...............................................................................................................................393 INSTALLATION..........................................................................................................................394 DISASSEMBLY...........................................................................................................................395 ASSEMBLY..............................................................................................................................396 STEERING VALVE............................................................................................................................399 REMOVAL...............................................................................................................................399 INSTALLATION..........................................................................................................................401 DISASSEMBLY...........................................................................................................................403 ASSEMBLY..............................................................................................................................405 STEERING CYLINDER.........................................................................................................................407 REMOVAL...............................................................................................................................407 INSTALLATION..........................................................................................................................408 DISASSEMBLY...........................................................................................................................409 ASSEMBLY..............................................................................................................................411 CENTER HINGE PIN..........................................................................................................................414 REMOVAL...............................................................................................................................414 INSTALLATION..........................................................................................................................421 44 MAINTENANCE STANDARD.......................................................................................................................428 STEERING VALVE............................................................................................................................429 STEERING CYLINDER MOUNT...................................................................................................................431 STEERING CYLINDER.........................................................................................................................432 CENTER HINGE PIN..........................................................................................................................433 STEERING LINKAGE..........................................................................................................................435 STEERING COLUMN AND GEAR BOX..............................................................................................................437 EMERGENCY STEERING PUMP (IF EQUIPPED).....................................................................................................438 DIVERTER VALVE (IF EQUIPPED)..............................................................................................................439 SECURITY VALVE (IF EQUIPPED)..............................................................................................................441 50 BRAKE SYSTEM...................................................................................................................................442 51 STRUCTURE AND FUNCTION.....................................................................................................................442 GENERAL...................................................................................................................................443 ACCUMULATOR...............................................................................................................................444 BRAKE BOOSTER.............................................................................................................................445 BRAKE.....................................................................................................................................450 PARKING BRAKE.............................................................................................................................452 BRAKE CALIPER.........................................................................................................................454 52 TESTING AND ADJUSTING......................................................................................................................455 STANDARD VALUE TABLE......................................................................................................................456 TOOL LIST FOR TESTING AND ADJUSTING.......................................................................................................457 MEASURING BRAKE PEDAL.....................................................................................................................458 BRAKE PERFORMANCE.........................................................................................................................459 CHECKING BRAKE PISTON LEAKAGE.............................................................................................................460 MEASURING WEAR OF BRAKE DISC..............................................................................................................461 AIR BLEEDING FROM BRAKE LINE..............................................................................................................462 PARKING BRAKE PERFORMANCE.................................................................................................................463 CHECKING AND ADJUSTING PARKING BRAKE......................................................................................................464 MEASURING CLEARANCE.......................................................................................................................466 TROUBLESHOOTING...........................................................................................................................467 TROUBLESHOOTING TABLE.................................................................................................................468 1. BRAKE IS INEFFECTIVE OR NOT VERY EFFECTIVE.....................................................................................468 2. BRAKE CANNOT BE RELEASED OR DRAGS..............................................................................................469 53 DISASSEMBLY AND ASSEMBLY...................................................................................................................470 BRAKE BOOSTER.............................................................................................................................471 REMOVAL...............................................................................................................................471 INSTALLATION..........................................................................................................................472 DISASSEMBLY...........................................................................................................................473 ASSEMBLY..............................................................................................................................475 PARKING BRAKE.............................................................................................................................477 REMOVAL...............................................................................................................................477 INSTALLATION..........................................................................................................................479 PARKING BRAKE PAD.........................................................................................................................481 REMOVAL...............................................................................................................................481 INSTALLATION..........................................................................................................................481 54 MAINTENANCE STANDARD.......................................................................................................................482 BRAKE BOOSTER.............................................................................................................................483 BRAKE.....................................................................................................................................484 PARKING BRAKE.............................................................................................................................485 60 WORK EQUIPMENT SYSTEM..........................................................................................................................486 61 STRUCTURE AND FUNCTION.....................................................................................................................486 GENERAL...................................................................................................................................487 HYDRAULIC CIRCUIT SYSTEM..................................................................................................................489 HYDRAULIC CIRCUIT DIAGRAM (FOR 2-SPOOL)...................................................................................................490 HYDRAULIC CIRCUIT DIAGRAM (FOR 3-SPOOL)...................................................................................................491 WORK EQUIPMENT LEVER LINKAGE..............................................................................................................492 BUCKET LINKAGE............................................................................................................................493 BUCKET POSITIONER AND BOOM KICK-OUT.......................................................................................................495 HYDRAULIC TANK............................................................................................................................497 OIL FILTER BYPASS VALVE...............................................................................................................499 BREATHER..............................................................................................................................499 HYDRAULIC AND STEERING PUMPS..............................................................................................................500 MAIN CONTROL VALVE (FOR 2-SPOOL)..........................................................................................................501 MAIN CONTROL VALVE (FOR 3-SPOOL)..........................................................................................................503 RELIEF VALVE..........................................................................................................................505 SAFETY VALVE (WITH SUCTION VALVE).....................................................................................................506 SUCTION VALVE.........................................................................................................................507 HYDRAULIC CYLINDER........................................................................................................................514 62 TESTING AND ADJUSTING......................................................................................................................515 STANDARD VALUE TABLE......................................................................................................................516 TOOL LIST FOR TESTING AND ADJUSTING.......................................................................................................517 MEASURING DUMP AND LIFT CONTROL LEVERS....................................................................................................518 ADJUSTING DUMP AND LIFT CONTROL LEVERS....................................................................................................519 MEASURING HYDRAULIC PRESSURE..............................................................................................................520 MEASURING LIFT ARM AND BUCKET.............................................................................................................522 MEASURING HYDRAULIC DRIFT OF LIFT ARM AND BUCKET..........................................................................................523 ADJUSTING BUCKET POSITIONER...............................................................................................................524 ADJUSTING BOOM KICK-OUT...................................................................................................................525 TROUBLESHOOTING...........................................................................................................................526 TROUBLESHOOTING TABLE.................................................................................................................527 1. LIFT ARM DOES NOT RISE.........................................................................................................527 2. LIFT ARM MOVES SLOWLY OR DOES NOT HAVE SUFFICIENT LIFTING POWER................................................................528 3. LIFT ARM MOVEMENT BECOMES SLOW AFTER IT REACHES A CERTAIN HEIGHT...............................................................529 4. BUCKET CANNOT BE HOLD DOWN WITH LIFT CYLINDER..................................................................................529 5. LIFT ARM HAS LARGE HYDRAULIC DRIFT.............................................................................................529 6. LIFT ARM MOVEMENT IS UNSTEADY DURING WORK......................................................................................529 7. LIFT ARM DESCENDS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "RAISE".............................................529 8. BUCKET DOES NOT TILT BACK......................................................................................................530 9. BUCKET MOVES SLOWLY OR HAS INSUFFICIENT TILT BACK POWER........................................................................531 10. BUCKET MOVEMENT BECOMES SLOW DURING TILT BACK.................................................................................532 11. BUCKET CANNOT BE HELD DOWN BY THE DUMP CYLINDER...............................................................................532 12. BUCKET HAS LARGE HYDRAULIC DRIFT..............................................................................................532 13. BUCKET MOVES UNSTEADILY WHEN MACHINE TRAVELS UNDER LOAD.......................................................................532 14. BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS SHIFTED FROM "HOLD" TO "TILT BACK".............................................532 15. CONTROL LEVERS OF LIFT ARM AND BUCKET MOVE STIFFLY AND SLUGGISHLY.............................................................533 63 DISASSEMBLY AND ASSEMBLY...................................................................................................................534 HYDRAULIC TANK............................................................................................................................535 REMOVAL...............................................................................................................................535 INSTALLATION..........................................................................................................................537 HYDRAULIC FILTER..........................................................................................................................539 REMOVAL...............................................................................................................................539 INSTALLATION..........................................................................................................................539 HYDRAULIC, STEERING PUMP..................................................................................................................540 REMOVAL...............................................................................................................................540 INSTALLATION..........................................................................................................................541 MAIN CONTROL VALVE........................................................................................................................542 REMOVAL...............................................................................................................................542 INSTALLATION..........................................................................................................................543 DISASSEMBLY...........................................................................................................................544 ASSEMBLY..............................................................................................................................546 DUMP CYLINDER.............................................................................................................................548 REMOVAL...............................................................................................................................548 INSTALLATION..........................................................................................................................550 LIFT CYLINDER.............................................................................................................................551 REMOVAL...............................................................................................................................551 INSTALLATION..........................................................................................................................552 LIFT AND DUMP CYLINDER....................................................................................................................553 DISASSEMBLY...........................................................................................................................553 ASSEMBLY..............................................................................................................................555 WORK EQUIPMENT............................................................................................................................558 REMOVAL...............................................................................................................................558 INSTALLATION..........................................................................................................................561 COUNTERWEIGHT.............................................................................................................................564 REMOVAL...............................................................................................................................564 INSTALLATION..........................................................................................................................564 64 MAINTENANCE STANDARD.......................................................................................................................565 MAIN CONTROL VALVE (FOR 2-SPOOL)..........................................................................................................566 MAIN CONTROL VALVE (FOR 3-SPOOL)..........................................................................................................568 DUMP CYLINDER.............................................................................................................................570 LIFT CYLINDER.............................................................................................................................571 BUCKET LINKAGE............................................................................................................................572 BUCKET POSITIONER AND BOOM KICK-OUT.......................................................................................................574 BUCKET....................................................................................................................................575 HYDRAULIC AND STEERING PUMP...............................................................................................................576 80 ELECTRIC AND ELECTRONIC SYSTEM.................................................................................................................577 81 STRUCTURE AND FUNCTION.....................................................................................................................577 ELECTRIC AND ELECTRONIC SYSTEM............................................................................................................578 ELECTRICAL CIRCUIT DIAGRAM................................................................................................................579 ENGINE STARTING CIRCUIT...................................................................................................................581 ENGINE STOP CIRCUIT.......................................................................................................................582 PREHEATING CIRCUIT........................................................................................................................583 PREHEATING AND AFTER-HEATING WITH HEATER SWITCH.......................................................................................583 PREHEATING WITH STARTING SWITCH.......................................................................................................584 COMBINATION SWITCH........................................................................................................................585 ELECTRICAL TRANSMISSION CONTROL...........................................................................................................586 ELECTRICAL TRANSMISSION CONTROL DIAGRAM...............................................................................................587 TRANSMISSION CUT-OFF SELECTOR SWITCH..................................................................................................588 NEUTRALIZER RELAY.....................................................................................................................589 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)...............................................................................................590 MONITOR PANEL.........................................................................................................................591 INDICATION ON MONITOR PANEL...........................................................................................................592 CONTROLLER............................................................................................................................594 SENSOR................................................................................................................................595 PROXIMITY SWITCH......................................................................................................................600 82 TESTING AND ADJUSTING......................................................................................................................604 ADJUSTING SPEEDOMETER MODULE..............................................................................................................605 TROUBLESHOOTING...........................................................................................................................607 CHECKS BEFORE TROUBLESHOOTING.........................................................................................................608 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART.....................................................................................609 CONNECTOR TERMINAL NUMBERS............................................................................................................611 PRECAUTION WHEN HANDLING CONNECTOR....................................................................................................616 ELECTRICAL WIRING DIAGRAM.............................................................................................................618 ELECTRICAL CIRCUIT SYSTEM.............................................................................................................619 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (E-1 TO E-16)...............................................................................624 E-1. ENGINE DOES NOT START........................................................................................................625 E-2. ENGINE DOES NOT STOP.........................................................................................................628 E-3. ENGINE STOPS WHEN MACHINE IS TRAVELING.......................................................................................628 E-4. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED........................................................630 E-5. MACHINE MOVES NEITHER IN FORWARD NOR IN REVERSE..............................................................................632 E-6. MACHINE MOVES IN REVERSE BUT NOT IN FORWARD..................................................................................636 E-7. MACHINE MOVES IN FORWARD BUT NOT IN REVERSE..................................................................................638 E-8. MACHINE MOVES FORWARD EVEN WHEN TRANSMISSION CONTROL LEVERS ARE IN NEUTRAL...................................................638 E-9. MACHINE MOVES IN REVERSE EVEN WHEN TRANSMISSION CONTROL LEVERS ARE IN NEUTRAL................................................640 E-10. MACHINE ALWAYS TRAVELS IN 1ST...............................................................................................640 E-11. TRANSMISSION DOES NOT CHANGE GEAR ..........................................................................................642 E-12. MACHINE TRAVELS WHEN TRANSMISSION CUT-OFF SWITCH IS ON .....................................................................644 E-13. TRANSMISSION CANNOT BE CUT-OFF..............................................................................................645 E-14. TRANSMISSION DOES NOT RETURN TO NEUTRAL.....................................................................................646 E-15. PREHEATING DOES NOT WORK....................................................................................................649 E-16. PREHEATING DOES NOT STOP....................................................................................................652 ELECTRONIC VEHICLE MONITORING SYSTEM..................................................................................................653 TROUBLESHOOTING CHART FOR ELECTRIC SYSTEM (E-1 TO E-16)...............................................................................654 E-1. ENGINE DOES NOT START........................................................................................................655 E-2. ENGINE DOES NOT STOP.........................................................................................................658 E-3. ENGINE STOPS WHEN MACHINE IS TRAVELING.......................................................................................658 E-4. TRANSMISSION IS NOT RETURNED TO NEUTRAL WHEN PARKING BRAKE IS APPLIED........................................................660 E-5. MACHINE MOVES NEITHER IN FORWARD NOR IN REVERSE..............................................................................662 E-6. MACHINE MOVES IN REVERSE BUT NOT IN FORWARD..................................................................................666 E-7. MACHINE MOVES IN FORWARD BUT NOT IN REVERSE..................................................................................668 E-8. MACHINE MOVES FORWARD EVEN WHEN TRANSMISSION CONTROL LEVERS ARE IN NEUTRAL...................................................668 E-9. MACHINE MOVES IN REVERSE EVEN WHEN TRANSMISSION CONTROL LEVERS ARE IN NEUTRAL................................................670 E-10. MACHINE ALWAYS TRAVELS IN 2ND...............................................................................................670 E-11. TRANSMISSION DOES NOT CHANGE GEAR ..........................................................................................672 E-12. TRANSMISSION CANNOT BE CUT-OFF..............................................................................................674 E-13. TRANSMISSION DOES NOT RETURN TO NEUTRAL.....................................................................................675 E-14. PREHEATING DOES NOT WORK....................................................................................................678 E-15. PREHEATING DOES NOT STOP....................................................................................................681 TROUBLESHOOTING TABLE FOR MONITORING SYSTEM...........................................................................................683 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M-1 TO M-32)(SERIAL NO. 10001-19999)..................................684 M-1 EVEN ENGINE IS STOPPED, BRAKE OIL LEVEL DISPLAY FLASHES.......................................................................685 M-2 EVEN ENGINE IS STOPPED, ENGINE OIL LEVEL DISPLAY FLASHES......................................................................685 M-3 EVEN ENGINE IS STOPPED, COOLANT LEVEL DISPLAY FLASHES.........................................................................688 M-4 BATTERY CHARGE DISPLAY FLASHES................................................................................................688 M-5 FUEL LEVEL DISPLAY FLASHES....................................................................................................690 M-6 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, BRAKE OIL LEVEL DISPLAY FLASHES.......................690 M-7 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, ENGINE OIL PRESSURE DISPLAY FLASHES...................692 M-8 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, COOLANT LEVEL DISPLAY FLASHES.........................692 M-9 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, BRAKE SERVO PRESSURE DISPLAY FLASHES (IF EQUIPPED)....694 M-10 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, COOLANT TEMPERATURE DISPLAY FLASHES..................694 M-11 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, TORQUE CONVERTER OIL TEMPERATURE DISPLAY FLASHES.....696 M-12 PARKING BRAKE DISPLAY LIGHTS UP, OR DOES NOT LIGHT UP........................................................................697 M-13 WORKING LAMP DISPLAY LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP..............................................................699 M-14 PREHEAT DISPLAY LIGHTS UP OR DOES NOT LIGHT UP...............................................................................701 M-15 FAILURE IN MAIN STEERING DISPLAY LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED)................................................703 M-16 EMERGENCY STEERING NORMAL DISPLAY LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED)...............................................705 M-17 TRANSMISSION CUT-OFF DISPLAY LIGHTS UP OR DOES NOT LIGHT UP..................................................................707 M-18 TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP OR DO NOT LIGHT UP.....................................................................709 M-19 SPEEDOMETER DISPLAY DOES NOT WORK............................................................................................713 M-20 HOURMETER DOES NOT WORK NORMALLY.............................................................................................715 M-21 ALL OR PART OF MONITOR PANEL DOES NOT WORK...................................................................................717 M-22 EVEN WHEN ENGINE IS STOPPED, ENGINE OIL PRESSURE DISPLAY FLASHES, OR BATTERY CHARGE DISPLAY FLASHES..........................719 M-23 NO LAMPS ON MONITOR LIGHT UP (IMMEDIATELY AFTER TURNING STARTING SWITCH TO ON, ENGINE STOPPED)...............................720 M-24 CENTRAL WARNING LAMP DOES NOT GO OUT.........................................................................................721 M-25 CENTRAL WARNING BUZZER DOES NOT STOP.........................................................................................723 M-26 NONE OF PANEL LAMPS ON MACHINE MONITOR LIGHT UP..............................................................................725 M-27 SOME OF PANEL LAMPS ON MACHINE MONITOR DO NOT LIGHT UP.......................................................................728 M-28 EMERGENCY ITEM IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND..................................................................730 M-29 EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMP DOES NOT FLASH............................................732 M-30 ABNORMALITY IN FUEL GAUGE....................................................................................................734 M-30-1 ABNORMALITY IN FUEL LEVEL SENSOR...........................................................................................735 M-31 ABNORMALITY IN COOLANT TEMPERATURE GAUGE.....................................................................................736 M-32 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE........................................................................738 TROUBLESHOOTING TABLE FOR MONITORING SYSTEM ......................................................................................740 TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M-1 TO M-32)(SERIAL NO. 20001 AND UP).................................741 M-1 EVEN ENGINE IS STOPPED, BRAKE OIL LEVEL DISPLAY FLASHES.......................................................................742 M-2 EVEN ENGINE IS STOPPED, ENGINE OIL LEVEL DISPLAY FLASHES......................................................................742 M-3 EVEN ENGINE IS STOPPED, COOLANT LEVEL DISPLAY FLASHES.........................................................................744 M-4 BATTERY CHARGE DISPLAY FLASHES................................................................................................744 M-5 FUEL LEVEL DISPLAY FLASHES....................................................................................................746 M-6 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, BRAKE OIL LEVEL DISPLAY FLASHES.......................746 M-7 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, ENGINE OIL PRESSURE DISPLAY FLASHES...................748 M-8 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, COOLANT LEVEL DISPLAY FLASHES.........................748 M-9 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, BRAKE SERVO PRESSURE DISPLAY FLASHES (IF EQUIPPED)....750 M-10 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, COOLANT TEMPERATURE DISPLAY FLASHES..................750 M-11 WHEN ENGINE IS RUNNING, EVEN THOUGH THERE IS NO ABNORMALITY IN MACHINE, TORQUE CONVERTER OIL TEMPERATURE DISPLAY FLASHES.....752 M-12 PARKING BRAKE DISPLAY LIGHTS UP, OR DOES NOT LIGHT UP........................................................................753 M-13 WORKING LAMP DISPLAY LIGHTS UP ABNORMALLY, OR DOES NOT LIGHT UP..............................................................755 M-14 PREHEAT DISPLAY LIGHTS UP OR DOES NOT LIGHT UP...............................................................................757 M-15 FAILURE IN MAIN STEERING DISPLAY LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED)................................................759 M-16 EMERGENCY STEERING NORMAL DISPLAY LIGHTS UP OR DOES NOT LIGHT UP (IF EQUIPPED)...............................................761 M-17 TRANSMISSION CUT-OFF DISPLAY LIGHTS UP OR DOES NOT LIGHT UP..................................................................763 M-18 TURN SIGNAL LAMPS, HIGH BEAM LIGHT UP OR DO NOT LIGHT UP.....................................................................765 M-19 SPEEDOMETER DISPLAY DOES NOT WORK............................................................................................769 M-20 HOURMETER DOES NOT WORK NORMALLY.............................................................................................771 M-21 ALL OR PART OF MONITOR PANEL DOES NOT WORK...................................................................................773 M-22 EVEN WHEN ENGINE IS STOPPED, ENGINE OIL PRESSURE DISPLAY FLASHES, OR BATTERY CHARGE DISPLAY FLASHES..........................774 M-23 NO LAMPS ON MONITOR LIGHT UP (IMMEDIATELY AFTER TURNING STARTING SWITCH TO ON, ENGINE STOPPED)...............................775 M-24 CENTRAL WARNING LAMP DOES NOT GO OUT.........................................................................................776 M-25 CENTRAL WARNING BUZZER DOES NOT STOP.........................................................................................777 M-26 NONE OF PANEL LAMPS ON MACHINE MONITOR LIGHT UP..............................................................................778 M-27 SOME OF PANEL LAMPS ON MACHINE MONITOR DO NOT LIGHT UP.......................................................................781 M-28 EMERGENCY ITEM IS FLASHING, BUT ALARM BUZZER DOES NOT SOUND..................................................................782 M-29 EMERGENCY ITEM OR NON-EMERGENCY ITEM IS FLASHING, BUT WARNING LAMP DOES NOT FLASH............................................783 M-30 ABNORMALITY IN FUEL GAUGE....................................................................................................785 M-30-1 ABNORMALITY IN FUEL LEVEL SENSOR...........................................................................................786 M-31 ABNORMALITY IN COOLANT TEMPERATURE GAUGE.....................................................................................787 M-32 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE........................................................................789 TABLE OF MONITOR REFERENCE VALUES.................................................................................................791 83 DISASSEMBLY AND ASSEMBLY...................................................................................................................798 MACHINE MONITOR...........................................................................................................................799 REMOVAL...............................................................................................................................799 INSTALLATION..........................................................................................................................799 90 OTHERS.........................................................................................................................................800 91 STRUCTURE AND FUNCTION.....................................................................................................................800 CAB.......................................................................................................................................801 AIR CONDITIONER (OPTION)..................................................................................................................802 AIR CONDITIONER PIPING................................................................................................................802 AIR CONDITIONER WIRING DIAGRAM........................................................................................................803 AIR CONDITIONER ELECTRIC CIRCUIT......................................................................................................803 AIR CONDITIONER UNIT..................................................................................................................804 AIR CONDITIONER COMPRESSOR............................................................................................................805 AIR CONDITIONER CONDENSOR.............................................................................................................805 AIR CONDITIONER DRY RESERVOIR.........................................................................................................806 93 DISASSEMBLY AND ASSEMBLY...................................................................................................................807 CAB.......................................................................................................................................808 REMOVAL...............................................................................................................................808 INSTALLATION..........................................................................................................................809 AIR CONDITIONER UNIT .....................................................................................................................810 REMOVAL...............................................................................................................................810 INSTALLATION..........................................................................................................................812 CONDENSER FOR AIR CONDITIONER.............................................................................................................814 REMOVAL...............................................................................................................................814 INSTALLATION..........................................................................................................................814 DRY RECEIVER .............................................................................................................................815 REMOVAL...............................................................................................................................815 INSTALLATION..........................................................................................................................815 COMPRESSOR FOR AIR CONDITIONER............................................................................................................816 REMOVAL...............................................................................................................................816 INSTALLATION..........................................................................................................................816 97 GEAR PUMP..................................................................................................................................817 GENERAL...................................................................................................................................817 GENERAL...............................................................................................................................818 PRINCIPLE OF OPERATION................................................................................................................819 PRESSURE LOADED TYPE GEAR PUMP........................................................................................................822 FIXED SIDE PLATE TYPE GEAR PUMP.......................................................................................................824 SA SERIES.................................................................................................................................825 STRUCTURE.............................................................................................................................826 TESTING AND ADJUSTING.................................................................................................................829 DISASSEMBLY...........................................................................................................................832 ASSEMBLY..............................................................................................................................836 MAINTENANCE STANDARD..................................................................................................................841
KOMATSU WA300-1, WA320-1 WHEEL LOADER SHOP MANUAL 10001 AND UP – PDF DOWNLOAD:
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Grant Kenji –
ya great easy