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Komatsu WA300L-3 Avance Loader Wheel Loader Shop Manual 53001 and up – PDF DOWNLOAD
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Komatsu WA300L-3 Avance Loader Wheel Loader Shop Manual
Book Code: SEBM017300
MACHINE MODEL SERIAL NUMBER
WA300L-3 53001 and up
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Description
Komatsu WA300L-3 Avance Loader Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA300L-3 Avance Loader Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA300L-3 Avance Loader
Serial Number: 53001 and up
Book Code: SEBM017300
Language: English
Pages: 571
File Format: Portable Document Format (PDF)
KOMATSU WA300L-3 AVANCE LOADER WHEEL LOADER SHOP MANUAL 53001 AND UP – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu WA300L-3 Avance Loader Wheel Loader Shop Manual
COVER.............................................................................................................................. 1 CONTENTS........................................................................................................................... 2 01 GENERAL......................................................................................................................... 3 GENERAL ASSEMBLY DRAWING....................................................................................................... 4 SPECIFICATIONS................................................................................................................. 5 WEIGHT TABLE................................................................................................................... 8 LIST OF LUBRICANT AND WATER.................................................................................................... 9 10 STRUCTURE AND FUNCTION.......................................................................................................... 11 POWER TRAIN.................................................................................................................... 12 POWER TRAIN SYSTEM............................................................................................................. 13 TORQUE CONVERTER,TRANSMISSION PIPING........................................................................................... 15 TORQUE CONVERTER............................................................................................................... 16 TORQUE CONVERTER OIL FILTER.................................................................................................... 18 TRANSMISSION................................................................................................................... 19 TRANSMISSION CONTROL VALVE..................................................................................................... 30 DRIVE SHAFT.................................................................................................................... 50 AXLE........................................................................................................................... 51 DIFFERENTIAL................................................................................................................... 53 FINAL DRIVE.................................................................................................................... 57 AXLE MOUNT,CENTER HINGE PIN.................................................................................................... 58 STEERING PIPING................................................................................................................ 60 STEERING COLUMN................................................................................................................ 61 PRIORITY VALVE................................................................................................................. 62 STEERING VALVE (ORBIT-ROLL).................................................................................................... 66 2-WAY RESTRICTOR VALVE......................................................................................................... 74 BRAKE PIPING................................................................................................................... 75 BRAKE VALVE.................................................................................................................... 76 BRAKE CHARGER VALVE............................................................................................................ 81 ACCUMULATOR (FOR BRAKE)........................................................................................................ 85 BRAKE.......................................................................................................................... 86 PARKING BRAKE CONTROL.......................................................................................................... 89 PARKING BRAKE.................................................................................................................. 90 HYDRAULIC PIPING............................................................................................................... 91 WORK EQUIPMENT LEVER LINKAGE................................................................................................... 93 HYDRAULIC TANK................................................................................................................. 94 MAIN CONTROL VALVE............................................................................................................. 96 WORK EQUIPMENT LINKAGE.........................................................................................................109 BUCKET POSITIONER AND BOOM KICK-OUT............................................................................................111 AIR CONDITIONER (OPT)..........................................................................................................115 CENTRAL PANEL (CLUSTER GAUGE)..................................................................................................116 SENSORS........................................................................................................................117 ENGINE STARTING CIRCUIT........................................................................................................120 ENGINE STOP CIRCUIT............................................................................................................121 ENGINE STOP SOLENOID...........................................................................................................122 AUTOMATIC PREHEATING CIRCUIT (Q.H.S. CONTROLLER)...............................................................................123 ELECTRIC TRANSMISSION CONTROL..................................................................................................127 KICK-DOWN SWITCH...............................................................................................................130 KICK-DOWN ELECTRICAL CIRCUIT DIAGRAM...........................................................................................131 TRANSMISSION CUT-OFF SWITCH....................................................................................................135 TRANSMISSION CUT-OFF FUNCTION..................................................................................................136 20 TESTING AND ADJUSTING...........................................................................................................138 STANDARD VALUE TABLE FOR ENGINE................................................................................................139 STANDARD VALUE TABLE FOR CHASSIS...............................................................................................140 STANDARD VALUE TABLE FOR ELECTRICAL PARTS......................................................................................146 TABLE OF TOOLS FOR TESTINGS,ADJUSTING,AND TROUBLESHOOTING......................................................................150 MEASURING ENGINE SPEED.........................................................................................................152 MEASURING EXHAUST GAS COLOR....................................................................................................154 ADJUSTING VALVE CLEARANCE......................................................................................................155 MEASURING COMPRESSION PRESSURE.................................................................................................157 MEASURING BLOW-BY PRESSURE.....................................................................................................158 TESTING AND ADJUSTING FUEL INJECTION TIMING....................................................................................159 MEASURING ENGINE OIL PRESSURE..................................................................................................160 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION..................................................................161 TESTING AND ADJUSTING ENGINE STOP SOLENOID LINKAGE.............................................................................162 ADJUSTING ACCELERATOR ACTUATOR CABLE...........................................................................................163 TESTING AND ADJUSTING TORQUE CONVERTER,TRANSMISSION OIL PRESSURE...............................................................164 PROCEDURE FOR MOVING MACHINE WHEN TRANSIMISSION VALVE FAILS....................................................................168 TESTING AND ADJUSTING STEERING OIL PRESSURE....................................................................................169 BLEEDING AIR FROM STEERING CIRCUIT.............................................................................................170 TESTING WHEEL BRAKE PERFORMANCE................................................................................................171 TESTING DROP IN WHEEL BRAKE OIL PRESSURE.......................................................................................172 MEASURING WHEEL BRAKE DISC WEAR................................................................................................173 BLEEDING AIR FROM WHEEL BRAKE CIRCUIT..........................................................................................174 TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE...........................................................175 MEASURING PARKING BRAKE PERFORMANCE............................................................................................177 TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE..............................................................................178 TESTING WEAR OF PARKING BRAKE DISC.............................................................................................179 MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE....................................................................................180 BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT.......................................................................................182 ADJUSTING WORK EQUIPMENT LEVER LINKAGE.........................................................................................183 ADJUSTING SAFETY LOCK LEVER....................................................................................................185 TESTING AND ADJUSTING OF BUCKET PROXIMITY SWITCH...............................................................................186 TESTING AND ADJUSTING OF BOOM PROXIMITY SWITCH.................................................................................187 TROUBLESHOOTING................................................................................................................189 POINTS TO REMEMBER WHEN TROUBLESHOOTING....................................................................................190 SEQUENCE OF EVENTS IN TROUBLESHOOTING......................................................................................191 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE...........................................................................192 CHECKS BEFORE TROUBLESHOOTING..............................................................................................200 METHOD OF USING TROUBLESHOOTING CHARTS.....................................................................................201 CONNECTOR TYPES AND MOUNTING LOCATIONS.....................................................................................209 CONNECTOR PIN ARRANGEMENT DIAGRAM..........................................................................................211 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.................................................................................215 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)..................................................................................223 S-1 STARTING PERFORMANCE IS POOR (STARTNG ALWAYS TAKES TIME)...........................................................224 S-2 ENGINE DOES NOT START..............................................................................................225 (1) ENGINE DOES NOT TURN...........................................................................................225 (2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED).........................................226 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).......................................227 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...............................................................228 S-4 ENGINE STOPS DURING OPERATIONS.....................................................................................229 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)..........................................................................230 S-6 ENGINE LACKS OUTPUT (NO POWER).....................................................................................231 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION).......................................................................232 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)..............................................................233 S-9 OIL BECOMES CONTAMINATED QUICKLY...................................................................................234 S-10 FUEL CONSUMPTION IS EXCESSIVE.....................................................................................235 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN.............................................236 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)................................................................237 S-13 OIL LEVEL RISES...................................................................................................238 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)..................................................................239 S-15 ABNORMAL NOISE IS MADE ...........................................................................................240 S-16 VIBRATION IS EXCESSIVE............................................................................................241 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)..............................................................................242 ELECTRICAL CIRCUIT DIAGRAM FOR ENGINE STARTING,STOP AND PREHEATING SYSTEM..............................................243 ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROL SYSTEM.............................................................244 E-1 ENGINE DOES NOT START..............................................................................................245 a) STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START............................................245 b) ENGINE STOP SOLENOID DOES NOT WORK..............................................................................248 E-2 ENGINE DOES NOT STOP...............................................................................................249 E-3 PREHEATING IS NOT CARRIED OUT......................................................................................250 E-4 PREHEATING REMAINS ACTUATED........................................................................................252 E-5 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT TRANSMISSION CUT-OFF WORKS NORMALLY)....253 E-6 TRANSMISSION DOES NOT WORK NORMALLY................................................................................254 a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION (ALWAYS STAYS IN 2ND)................................................256 b) PROBLEM IN H-L CIRCUIT..........................................................................................257 c) PROBLEM IN SPEED CIRCUIT........................................................................................258 d) PROBLEM IN 4TH CIRCUIT (DOES NOT ENTER 4TH).....................................................................259 e) CONTACT IN H-L CIRCUIT..........................................................................................260 f) CONTACT IN SPEED CIRCUIT........................................................................................261 g) CONTACT IN 4TH CIRCUIT (ALWAYS STAYS IN 4TH)....................................................................262 h) PROBLEM IN FORWARD CIRCUIT (REVERSE IS NORMAL)..................................................................263 i) PROBLEM IN REVERSE CIRCUIT (FORWARD IS NORMAL)..................................................................265 j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE (DOES NOT TRAVEL FORWARD OR IN REVERSE).......................267 k) CONTACT IN FORWARD CIRCUIT......................................................................................269 l) CONTACT IN REVERSE CIRCUIT......................................................................................271 m) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE...............................................................273 E-7 KICK-DOWN SWITCH DOES NOT WORK (THE REGULAR F1 TO F4 SHIFTS NORMALLY)..............................................274 E-8 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT HOLD IN POSITION)................276 E-9 KICK-DOWN IS NOT CANCELED..........................................................................................276 a) NOT CANCELED WHEN F/R LEVER IS OPERATED FROM F TO N OR R........................................................276 b) NOT CANCELED WHEN SPEED LEVER IS OPERATED FROM 2 TO OTHER POSITION..............................................277 E-10 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND.....................................................279 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)................................................................280 POWER TRAIN............................................................................................................281 H-1 MACHINE DOES NOT START.........................................................................................281 H-2 TRAVEL SPEED IS SLOW,THRUSTING POWER IS WEAK,LACKS POWER ON SLOPES.............................................283 H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR.........................................................285 H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR......................................................286 H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH.......................................................................287 STEERING SYSTEM........................................................................................................288 H-6 STEERING WHEEL DOES NOT TURN...................................................................................288 H-7 STEERING IS HEAVY..............................................................................................289 H-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK..............................................................290 BRAKE SYSTEM...........................................................................................................291 H-9 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...................................................................291 H-10 BRAKES ARE NOT RELEASED OR BRAKES DRAG........................................................................292 WORK EQUIPMENT.........................................................................................................293 H-11 BOOM DOES NOT RISE............................................................................................293 H-12 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER.............................................................294 H-13 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT......................................................295 H-14 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)....................................................295 H-15 EXCESSIVE HYDRAULIC DRIFT OF BOOM.............................................................................295 H-16 BOOM SHAKES DURING OPERATION..................................................................................295 H-17 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE......................................296 H-18 BUCKET DOES NOT TILT BACK.....................................................................................297 H-19 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER..............................................................298 H-20 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION.......................................................299 H-21 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER..................................................................299 H-22 EXCESSIVE HYDRAULIC DRIFT OF BUCKET...........................................................................299 H-23 BUCKET SHAKES DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD)...........................................300 H-24 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT.....................................300 H-25 BOOM,BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY..................................................301 30 DISASSEMBLY AND ASSEMBLY........................................................................................................302 METHOD OF USING MANUAL.........................................................................................................304 PRECAUTIONS WHEN CARRYING OUT OPERATION........................................................................................305 SPECIAL TOOL LIST..............................................................................................................307 SKETCHES OF SPECIAL TOOLS......................................................................................................310 STARTING MOTOR.................................................................................................................312 REMOVAL AND INSTALLATION...................................................................................................312 ALTERNATOR.....................................................................................................................313 REMOVAL AND INSTALLATION...................................................................................................313 ENGINE OIL COOLER CORE.........................................................................................................314 REMOVAL AND INSTALLATION...................................................................................................314 FUEL INJECTION PUMP............................................................................................................315 REMOVAL....................................................................................................................315 INSTALLATION...............................................................................................................317 WATER PUMP.....................................................................................................................320 REMOVAL AND INSTALLATION...................................................................................................320 TURBOCHARGER...................................................................................................................321 REMOVAL AND INSTALLATION...................................................................................................321 NOZZLE HOLDER..................................................................................................................322 REMOVAL....................................................................................................................322 INSTALLATION...............................................................................................................323 THERMOSTAT.....................................................................................................................324 REMOVAL AND INSTALLATION...................................................................................................324 ENGINE HOOD....................................................................................................................325 REMOVAL....................................................................................................................325 INSTALLATION...............................................................................................................326 CYLINDER HEAD..................................................................................................................327 REMOVAL....................................................................................................................327 INSTALLATION...............................................................................................................331 RADIATOR.......................................................................................................................334 REMOVAL....................................................................................................................334 INSTALLATION...............................................................................................................335 ENGINE.........................................................................................................................336 REMOVAL....................................................................................................................336 INSTALLATION...............................................................................................................339 TORQUE CONVERTER CHARGING PUMP.................................................................................................340 REMOVAL AND INSTALLATION...................................................................................................340 TORQUE CONVERTER,TRANSMISSION..................................................................................................341 REMOVAL....................................................................................................................341 INSTALLATION...............................................................................................................344 TORQUE CONVERTER...............................................................................................................345 DISASSEMBLY................................................................................................................345 ASSEMBLY...................................................................................................................347 TRANSMISSION ..................................................................................................................349 DISASSEMBLY................................................................................................................349 ASSEMBLY...................................................................................................................359 CLUTCH PACK....................................................................................................................372 DISASSEMBLY................................................................................................................372 ASSEMBLY...................................................................................................................378 PARKING BRAKE..................................................................................................................391 DISASSEMBLY................................................................................................................391 ASSEMBLY...................................................................................................................394 TRANSMISSION CONTROL VALVE.....................................................................................................397 REMOVAL....................................................................................................................397 INSTALLATION...............................................................................................................398 DISASSEMBLY................................................................................................................399 ASSEMBLY...................................................................................................................401 DRIVE SHAFT....................................................................................................................403 DISASSEMBLY................................................................................................................403 ASSEMBLY...................................................................................................................405 FRONT AXLE.....................................................................................................................407 REMOVAL....................................................................................................................407 INSTALLATION...............................................................................................................409 REAR AXLE......................................................................................................................410 REMOVAL....................................................................................................................410 INSTALLATION...............................................................................................................414 DIFFERENTIAL...................................................................................................................415 DISASSEMBLY................................................................................................................415 ASSEMBLY...................................................................................................................419 AXLE HOUSING...................................................................................................................429 DISASSEMBLY................................................................................................................429 ASSEMBLY...................................................................................................................436 CENTER HINGE PIN...............................................................................................................445 REMOVAL....................................................................................................................445 INSTALLATION...............................................................................................................450 STEERING VALVE.................................................................................................................454 REMOVAL....................................................................................................................454 INSTALLATION...............................................................................................................455 DISASSEMBLY................................................................................................................456 ASSEMBLY...................................................................................................................459 PRIORITY VALVE.................................................................................................................463 REMOVAL AND INSTALLATION...................................................................................................463 STEERING CYLINDER..............................................................................................................464 REMOVAL AND INSTALLATION...................................................................................................464 RIGHT BRAKE VALVE (TANDEM).....................................................................................................465 DISASSEMBLY................................................................................................................465 ASSEMBLY...................................................................................................................466 LEFT BRAKE VALVE (SINGLE)......................................................................................................467 DISASSEMBLY................................................................................................................467 ASSEMBLY...................................................................................................................468 PARKING BRAKE DISC.............................................................................................................469 REMOVAL....................................................................................................................469 INSTALLATION...............................................................................................................470 HYDRAULIC TANK.................................................................................................................471 REMOVAL AND INSTALLATION...................................................................................................471 HYDRAULIC FILTER...............................................................................................................472 REMOVAL AND INSTALLATION...................................................................................................472 HYDRAULIC COOLER...............................................................................................................473 REMOVAL AND INSTALLATION...................................................................................................473 HYDRAULIC,STEERING PUMP........................................................................................................474 REMOVAL AND INSTALLATION...................................................................................................474 MAIN CONTROL VALVE.............................................................................................................475 REMOVAL....................................................................................................................475 INSTALLATION...............................................................................................................476 DISASSEMBLY................................................................................................................477 ASSEMBLY...................................................................................................................479 BUCKET CYLINDER................................................................................................................481 REMOVAL....................................................................................................................481 INSTALLATION...............................................................................................................482 BOOM CYLINDER..................................................................................................................483 REMOVAL....................................................................................................................483 INSTALLATION...............................................................................................................484 HYDRAULIC CYLINDER.............................................................................................................485 DISASSEMBLY................................................................................................................485 ASSEMBLY...................................................................................................................488 WORK EQUIPMENT.................................................................................................................492 REMOVAL....................................................................................................................492 INSTALLATION...............................................................................................................495 COUNTERWEIGHT..................................................................................................................498 REMOVAL AND INSTALLATION...................................................................................................498 FUEL TANK......................................................................................................................499 REMOVAL....................................................................................................................499 INSTALLATION...............................................................................................................500 CAB............................................................................................................................501 REMOVAL....................................................................................................................501 INSTALLATION...............................................................................................................502 FLOOR FRAME....................................................................................................................503 REMOVAL....................................................................................................................503 INSTALLATION...............................................................................................................505 ACCUMULATOR CHARGE VALVE.......................................................................................................506 REMOVAL AND INSTALLATION...................................................................................................506 ACCUMULATOR UNIT...............................................................................................................507 REMOVAL AND INSTALLATION...................................................................................................507 AIR CONDITIONER UNIT...........................................................................................................508 REMOVAL....................................................................................................................508 INSTALLATION...............................................................................................................513 AIR CONDITIONER CONDENSER......................................................................................................514 REMOVAL....................................................................................................................514 INSTALLATION...............................................................................................................515 DRY RECEIVER...................................................................................................................516 REMOVAL AND INSTALLATION...................................................................................................516 AIR CONDITIONER COMPRESSOR.....................................................................................................517 REMOVAL....................................................................................................................517 INSTALLATION...............................................................................................................518 MONITOR PANEL..................................................................................................................519 REMOVAL AND INSTALLATION...................................................................................................519 40 MAINTENANCE STANDARD............................................................................................................520 ENGINE MOUNT,TRANSMISSION MOUNT................................................................................................521 TORQUE CONVERTER CHARGING PUMP.................................................................................................522 TORQUE CONVERTER...............................................................................................................523 TRANSMISSION...................................................................................................................524 TRANSMISSION CONTROL VALVE.....................................................................................................532 DRIVE SHAFT....................................................................................................................536 DIFFERENTIAL (1/2).............................................................................................................537 DIFFERENTIAL (2/2).............................................................................................................538 FINAL DRIVE....................................................................................................................540 AXLE MOUNT.....................................................................................................................542 CENTER HINGE PIN...............................................................................................................543 STEERING COLUMN................................................................................................................545 PRIORITY VALVE.................................................................................................................546 STEERING CYLINDER MOUNT........................................................................................................547 BRAKE..........................................................................................................................548 BRAKE VALVE....................................................................................................................549 PARKING BRAKE..................................................................................................................552 HYDRAULIC PUMP (STEERING,HYDRAULIC,BRAKE CHARGE PUMP)..........................................................................553 MAIN CONTROL VALVE.............................................................................................................554 HYDRAULIC CYLINDER.............................................................................................................558 WORK EQUIPMENT LINKAGE.........................................................................................................559 BUCKET.........................................................................................................................561 BUCKET POSITIONER AND BOOM KICK-OUT............................................................................................562 90 OTHERS..........................................................................................................................563 TORQUE CONVERTER,TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM........................................................................564 BRAKE HYDRAULIC CIRCUIT DIAGRAM................................................................................................565 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.......................................................................................567 ELECTRIC CIRCUIT DIAGRAM (1/3).................................................................................................569 ELECTRIC CIRCUIT DIAGRAM (2/3).................................................................................................570 ELECTRIC CIRCUIT DIAGRAM (3/3).................................................................................................571
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