Komatsu WA300L-3 Avance Wheel Loader Shop Manual SEBM017300 PDF

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

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

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

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TABLE OF CONTENTS:

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

MACHINE MODEL    SERIAL NUMBER
WA300L-3                  53001 and up

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

S.V 24/12/24