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KOMATSU WA320-5 WA320L-5 WHEEL LOADER SHOP MANUAL – PDF DOWNLOAD
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KOMATSU WA320-5 WA320L-5 WHEEL LOADER SHOP MANUAL – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA320-5 WA320L-5 WHEEL LOADER SHOP MANUAL – PDF DOWNLOAD
Language : English
Pages : 844
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA320-5 WA320L-5 WHEEL LOADER SHOP MANUAL – PDF DOWNLOAD
MAIN MENU.................................................................................................................................................................................... 0 COVER........................................................................................................................................................................................ 1 CONTENTS..................................................................................................................................................................................... 2 SAFETY....................................................................................................................................................................................... 6 SAFETY NOTICE............................................................................................................................................................................ 6 FOREWORD..................................................................................................................................................................................... 8 GENERAL.................................................................................................................................................................................. 8 HOW TO READ THE SHOP MANUAL.............................................................................................................................................................. 9 HOISTING INSTRUCTIONS.................................................................................................................................................................... 10 METHOD OF DISASSMBLING, CONNECTING PUSH-PULL TYPE COUPLER................................................................................................................................ 11 COATING MATERIALS........................................................................................................................................................................ 13 STANDARD TIGHTING TORQUE................................................................................................................................................................. 15 ELECTRIC WIRE CODE....................................................................................................................................................................... 18 CONVERSION TABLE......................................................................................................................................................................... 19 UNITS.................................................................................................................................................................................... 25 01 GENERAL................................................................................................................................................................................... 27 GENERAL ASSEMBLY DRAWINGS................................................................................................................................................................ 28 SPECIFICATIONS........................................................................................................................................................................... 29 WEIGHT TABLE............................................................................................................................................................................. 33 LIST OF LUBRICANT AND COOLANT............................................................................................................................................................ 35 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.............................................................................................................................................. 39 ENGINE MOUNT AND TRANSFER MOUNT.......................................................................................................................................................... 40 DAMPER................................................................................................................................................................................... 41 COOLING SYSTEM........................................................................................................................................................................... 42 POWER TRAIN.............................................................................................................................................................................. 43 POWER TRAIN SYSTEM DIAGRAM............................................................................................................................................................... 44 DRIVE SHAFT (PROPELLER SHAFT)............................................................................................................................................................ 46 HST HYDRAULIC PIPING DIAGRAM............................................................................................................................................................. 47 HST PUMP................................................................................................................................................................................. 48 HIGH PRESSURE RELIEF VALVE............................................................................................................................................................... 50 LOW PRESSURE RELIEF VALVE................................................................................................................................................................ 52 HST CHARGE PUMP.......................................................................................................................................................................... 53 SPEED RELATED VALVE (DA VALVE)........................................................................................................................................................... 54 HIGH PRESSURE CUT OFF VALVE.............................................................................................................................................................. 55 HST MOTOR................................................................................................................................................................................ 56 EP SERVO VALVE........................................................................................................................................................................... 59 HA SERVO VALVE........................................................................................................................................................................... 60 FORWARD-REVERSE SHUTTLE VALVE............................................................................................................................................................ 61 TRANSFER................................................................................................................................................................................. 62 CLUTCH SOLENOID VALVE.................................................................................................................................................................... 73 AXLE..................................................................................................................................................................................... 74 DIFFERENTIAL............................................................................................................................................................................. 76 LIMITED SLIP DIFFERENTIAL................................................................................................................................................................ 84 FINAL DRIVE.............................................................................................................................................................................. 88 AXLE MOUNTING AND CENTER HINGE PIN....................................................................................................................................................... 90 STEERING PIPING.......................................................................................................................................................................... 95 STEERING COLUMN.......................................................................................................................................................................... 96 PRIORITY VALVE........................................................................................................................................................................... 97 ORBIT ROLL VALVE.........................................................................................................................................................................100 CUSHION VALVE............................................................................................................................................................................108 STEERING CYLINDER........................................................................................................................................................................109 EMERGENCY STEERING PIPING................................................................................................................................................................111 EMERGENCY STEERING VALVE.................................................................................................................................................................112 BRAKE PIPING.............................................................................................................................................................................115 BRAKE VALVE..............................................................................................................................................................................116 INCHING VALVE............................................................................................................................................................................120 CHARGE VALVE.............................................................................................................................................................................122 ACCUMULATOR (FOR BRAKE)..................................................................................................................................................................126 SLACK ADJUSTER...........................................................................................................................................................................128 BRAKE....................................................................................................................................................................................130 PARKING BRAKE CONTROL....................................................................................................................................................................132 PARKING BRAKE............................................................................................................................................................................133 HYDRAULIC PIPING.........................................................................................................................................................................134 WORK EQUIPMENT LEVER LINKAGE.............................................................................................................................................................136 HYDRAULIC TANK...........................................................................................................................................................................138 4-GEAR PUMP UNIT.........................................................................................................................................................................140 ACCUMULATOR (FOR PPC CIRCUIT)............................................................................................................................................................142 LOCK VALVE...............................................................................................................................................................................143 E.C.S.S. VALVE...........................................................................................................................................................................144 ACCUMULATOR (FOR E.C.S.S.)...............................................................................................................................................................146 HYDRAULIC PIPING OF COOLING SYSTEM.......................................................................................................................................................147 COOLING FAN MOTOR........................................................................................................................................................................148 WORK EQUIPMENT CONTROL VALVE.............................................................................................................................................................151 WORK EQUIPMENT PPC VALVE.................................................................................................................................................................172 ATTACHMENT PPC VALVE.....................................................................................................................................................................184 WORK EQUIPMENT LINKAGE...................................................................................................................................................................188 BUCKET...................................................................................................................................................................................190 BUCKET POSITIONER AND BOOM KICK-OUT......................................................................................................................................................192 WORK EQUIPMENT CYLINDER..................................................................................................................................................................198 AIR CONDITIONER..........................................................................................................................................................................199 MACHINE MONITORING SYSTEM................................................................................................................................................................200 MACHINE MONITOR..........................................................................................................................................................................210 LIST OF ITEMS DISPLAYED ON MONITOR.......................................................................................................................................................211 ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)................................................................................................................................................237 HST CONTROLLER...........................................................................................................................................................................241 ENGINE START CIRCUIT.....................................................................................................................................................................242 ENGINE STOP CIRCUIT......................................................................................................................................................................244 PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM).........................................................................................................................................245 PARKING BRAKE CIRCUIT....................................................................................................................................................................246 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM..............................................................................................................................................249 SENSORS..................................................................................................................................................................................250 20 TESTING AND ADJUSTING.....................................................................................................................................................................259 STANDARD VALUE TABLE FOR ENGINE..........................................................................................................................................................260 STANDARD VALUE TABLE FOR CHASSIS.........................................................................................................................................................261 TESTING AND ADJUSTING....................................................................................................................................................................265 TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING....................................................................................................................................266 MEASURING ENGINE SPEED...............................................................................................................................................................268 MEASURING EXHAUST GAS COLOR..........................................................................................................................................................269 ADJUSTING VALVE CLEARANCE............................................................................................................................................................271 MEASURING COMPRESSION PRESSURE.......................................................................................................................................................272 MEASURING BLOW-BY PRESSURE...........................................................................................................................................................273 TESTING AND ADJUSTING FUEL INJECTION TIMING..........................................................................................................................................274 MEASURING ENGINE OIL PRESSURE........................................................................................................................................................275 MEASURING, TESTING OPERATING FORCE OF ACCELERATOR PEDAL..............................................................................................................................276 ADJUSTING ENGINE STOP SOLENOID.......................................................................................................................................................278 ADJUSTING ENGINE SPEED SENSOR........................................................................................................................................................279 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION........................................................................................................................279 MEASURING DIRECTIONAL LEVER..........................................................................................................................................................280 TESTING AND ADJUSTING HST OIL PRESSURE...............................................................................................................................................280 MEASURING CLUTCH CONTROL PRESSURE....................................................................................................................................................285 TESTING AND ADJUSTING STEERING WHEEL.................................................................................................................................................286 TESTING AND ADJUSTING STEERING OIL PRESSURE..........................................................................................................................................287 BLEEDING AIR FROM STEERING CIRCUIT...................................................................................................................................................288 TESTING HYDRAULIC FAN................................................................................................................................................................289 MEASURING BRAKE PEDAL................................................................................................................................................................290 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE............................................................................................................................................291 MEASURING BRAKE PERFORMANCE..........................................................................................................................................................292 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE....................................................................................................................................293 MEASURING BRAKE OIL PRESSURE.........................................................................................................................................................294 MEASURING WEAR OF BRAKE DISC.........................................................................................................................................................296 BLEEDING AIR FROM BRAKE CIRCUIT......................................................................................................................................................297 MEASURING PARKING BRAKE PERFORMANCE..................................................................................................................................................298 TESTING AND ADJUSTING PARKING BRAKE LINKAGE..........................................................................................................................................299 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER.................................................................................................................................300 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE..............................................................................................................................301 TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE................................................................................................................................302 BLEEDING AIR.........................................................................................................................................................................304 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....................................................................................................................................305 TESTING AND ADJUSTING BUCKET POSITIONER..............................................................................................................................................305 TESTING AND ADJUSTING OF BOOM KICK-OUT...............................................................................................................................................307 CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP.....................................................................................................................................308 PROCEDURE FOR CHECKING DIODE.........................................................................................................................................................309 METHOD OF CONNECTING T-ADAPTER FOR HST CONTROLLER....................................................................................................................................310 SPECIAL FUNCTIONS OF MACHINE MONITOR.................................................................................................................................................311 FLOW OF MODES AND FUNCTIONS..........................................................................................................................................................312 FAILURE CODE TABLE..................................................................................................................................................................320 PM CLINIC INSPECTION CHART...........................................................................................................................................................330 TROUBLESHOOTING..........................................................................................................................................................................333 POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................................................................334 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................................................................335 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE............................................................................................................................................336 CHECK BEFORE TROUBLESHOOTING.........................................................................................................................................................344 CATEGORIES, PROCEDURE, AND METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................................................345 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO...........................................................................................................................346 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...........................................................................................................................................349 T-ADAPTER TABLE......................................................................................................................................................................371 CONNECTOR TYPES AND MOUNTING LOCATIONS...............................................................................................................................................374 CONNECTOR LAYOUT DRAWING.............................................................................................................................................................381 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)..................................................................................................................................386 BEFORE TROUBLESHOOTING CODE DISPLAY..............................................................................................................................................387 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM.........................................................................................................................................389 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...................................................................................................................................390 FAILURE CODE [989F00] (HST MOTOR PROTECTION CAUTION (00))........................................................................................................................392 FAILURE CODE [DHH1KX] (HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE REANGE (KX)).................................................................................................393 FAILURE CODE [DLE2LC] (ENGINE REVOLUTION SENSOR SPEED SIGNAL MISMATCH (LC))......................................................................................................395 FAILURE CODE [DW26KZ] (MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))...........................................................................................397 FAILURE CODE [DX19LZ] (MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))...........................................................................................399 FAILURE CODE [DX20KZ] (CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))............................................................................................401 TROUBLESHOOTING CODE [HST-1] (DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))..........................................................................403 TROUBLESHOOTING CODE [HST-2] (TRAVEL SPEED DOES NOT SHIFT).......................................................................................................................405 TROUBLESHOOTING CODE [HST-3] HST OUTPUT CONTROL (TRACTION CONTROL) CANNOT BE CONTROLLED..........................................................................................409 TROUBLESHOOTING CODE [HST-4] (TRAVEL SPEED LIMIT CANNOT BE CHANGED WHEN GEAR SPEE SELECTOR SWITCH IS IN "1ST" POSITION)..........................................................411 TROUBLESHOOTING CODE [HST-5] (TRAVEL SPEED IS NOT INCREASED).....................................................................................................................413 TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM (ECSS MODE)..................................................................................................................................416 RELATED ELECTRICAL CIRCUIT DIAGRAM...............................................................................................................................................417 ECSS-1 MALFUNCTION OF TRAVEL DAMPER..............................................................................................................................................418 TROUBLESHOOTING OF MONITOR SYSTEM (MON MODE).........................................................................................................................................423 BEFORE TROUBLESHOOTING CODE DISPLAY..............................................................................................................................................426 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM.........................................................................................................................................428 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...................................................................................................................................429 FAILURE CODE [15B0NX] (HST OIL FILTER CLOGGED (NX))..............................................................................................................................431 FAILURE CODE [2G42ZG] (DECREASED BRAKE OIL PRESSURE (ZG))........................................................................................................................432 FAILURE CODE [989F00] (HST MOTOR PROTECTION CAUTION (00))........................................................................................................................433 FAILURE CODE [989FN1] (HST OVERRUNNING (N1)).....................................................................................................................................434 FAILURE CODE [AA1ANX] (CLOGGING OF AIR CLEANER (NX)).............................................................................................................................436 FAILURE CODE [AB00L6] (DEFECTIVE BATTERY CHARGING CIRCUIT (L6))..................................................................................................................438 FAILURE CODE [AB00MA] (DEFECTIVE BATTERY CHARGING CIRCUIT (MA))..................................................................................................................439 FAILURE CODE [B@BAZG] (DEGREASED ENGINE OIL PRESSURE (ZG)).......................................................................................................................440 FAILURE CODE [B@BAZK] LOWERING OF ENGINE OIL LEVEL (ZK)..........................................................................................................................441 FAILURE CODE [B@BCNS] (ENGINE COOLANT TEMPERATURE OVERHEATING (NS))..............................................................................................................442 FAILURE CODE [B@BCZK] (ALARM INDICATING LOW COOLANT LEVEL (ZK))..................................................................................................................443 FAILURE CODE [B@C7NS] (AXLE OIL TEMPERATURE OVERHEATING (NS))....................................................................................................................444 FAILURE CODE [B@CRNS] (HST OIL TEMPERATURE OVERHEATING (NS)).....................................................................................................................445 FAILURE CODE [D5ZHL6] (STARTING SWITCH "C" (IGN "C") INPUT FAILURE (L6)).........................................................................................................446 FAILURE CODE [DAF0KT] (CONTROLLER INSIDE FAILURE (KT))...........................................................................................................................448 FAILURE CODE [DAJ0KR] (HST CONTROLLER COMMUNICATION FAILURE (KR))................................................................................................................450 FAILURE CODE [DD15LD] (MONITOR PANEL MODE SELECTOR SWITCH 1 [ ] (PANEL SWITCH [] INPUT ERROR (LD)) .............................................................................452 FAILURE CODE [DD16LD] (MONITOR PANEL MODE SELECTOR SWITCH 1 [<>] (PANEL SWITCH 2) INPUT ERROR (LD))..............................................................................453 FAILURE CODE [DD17LD] (MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SWITCH 3) INPUT ERROR (LD))...............................................................................454 FAILURE CODE [DD18LD] (MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SWITCH 4) INPUT ERROR (LD))...............................................................................455 FAILURE CODE [DDK3KB] (MULTIPLE DIRECTIONAL LEVEL FR SIGNAL INPUT (KB))..........................................................................................................456 FAILURE CODE [DDS5L6] (DECREASED STEERING OIL PRESSURE (L6)).....................................................................................................................458 FAILURE CODE [DGE2KX] (ENGINE COOLANT TEMPERATURE (HIGH TEMPERATURE) SENSOR SYSTEM FAILURE (KX)).................................................................................459 FAILURE CODE [DGE3L6] (ENGINE COOLANT TEMPERATURE (LOW TEMPERTURE) SENSOR SYSTEM FAILURE (L6))...................................................................................460 FAILURE CODE [DGH1KX] (HST OIL TEMPERATURE SENSOR SYSTEM FAILURE (KX))...........................................................................................................461 FAILURE CODE [DGR4KA] (AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY (KA))....................................................................................................462 FAILURE CODE [DGR4KX] (AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE (KX))..........................................................................................................463 FAILURE CODE [DHE4L6] (ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY(L6))......................................................................................................464 TROUBLESHOOTING CODE [MON-1] (THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)................................................................................................466 TROUBLESHOOTING CODE [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON).............................................................................................470 TROUBLESHOOTING CODE [MON-3] (THE ENGINE COOLANT TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON, OR AFTER THE ENGINE STARTS, THE ENGINE COOLANT TEMPERATURE GAUGE DOES NOT RISE).....471 TROUBLESHOOTING CODE [MON-4] (THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON, OR AFTER THE ENGINE STARTS, THE HST OIL TEMPERATURE GAUGE DOE NOT RISE)....................472 TROUBLESHOOTING CODE [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE)....................................................................................................473 TROUBLESHOOTING CODE [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON).........................................................................................474 TROUBLESHOOTING CODE [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON]..........................................................................................475 TROUBLESHOOTING CODE [MON-8] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON)..............................................................................476 TROUBLESHOOTING CODE [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [ ] (PANEL SWITCH 1))........................................................................477 TROUBLESHOOTING CODE [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1 [} (PANEL SWITCH 2).........................................................................478 TROUBLESHOOTING CODE [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [<] (PANEL SWITCH 3)).......................................................................479 TROUBLESHOOTING CODE [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2 [>] (PANEL SWITCH 4)).......................................................................480 TROUBLESHOOTING CODE [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP)..........................................................................................................482 TROUBLESHOOTING CODE [MON-14] ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT UP....................................................................................................484 TROUBLESHOOTING CODE [MON-15] AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP..............................................................................................486 TROUBLESHOOTING CODE [MON-16] THE WIPER DOES NOT FUNCTION........................................................................................................................488 TROUBLESHOOTING CODE [MON-17] THE LAMPS DO NOT WORK PROPERLY.....................................................................................................................488 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)........................................................................................................................................489 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM.........................................................................................................................................490 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE...................................................................................................................................491 TROUBLESHOOTING CODE [E-1] (THE ENGINE DOES NOT START)...........................................................................................................................494 TROUBLESHOOTING CODE [E-2] (THE ENGINE DOES NOT STOP)............................................................................................................................500 TROUBLESHOOTING CODE [E-3] (PREHEATING IS IMPOSSIBLE OR CONSTANT)................................................................................................................502 TROUBLESHOOTING CODE [E-4] (THE PARKING BRAKE (MECHANICAL TYPE) DOES NOT FUNCTION)...............................................................................................506 TROUBLESHOOTING CODE [E-5] (DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION)...................................................................................................512 TROUBLESHOOTING CODE [E-6] (DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)...............................................................................................516 TROUBLESHOOTING CODE [E-7] (DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION).......................................................................................519 TROUBLESHOOTING CODE [E-8] (TRAVEL DIRECTION IS NOT CHANGED NORMALLY)............................................................................................................520 TROUBLESHOOTING CODE [E-9] (THE WIPER DOES NOT FUNCTION).........................................................................................................................526 TROUBLESHOOTING CODE [E-10] (THE WINDOW WASHER DOES NOT FUNCTION)................................................................................................................532 TROUBLESHOOTING CODE [E-11] (LAMPS DO NOT WORK PROPERLY).........................................................................................................................536 TROUBLESHOOTING CODE [E-12] (THE HORN DOES NOT SOUND)............................................................................................................................548 TROUBLESHOOTING CODE [E-13] (DEFECTIVE AIR CONDITIONER)..........................................................................................................................550 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE).............................................................................................................................563 METHOD OF USING TROUBLESHOOTING CHART............................................................................................................................................564 FAILURE CODE AND CAUSE TABLE.....................................................................................................................................................566 H-1 THE MACHINE DOES NOT START...................................................................................................................................................568 H-2 THE TRAVEL SPEED IS SLOW.....................................................................................................................................................569 H-3 THE THRUSTING FORCE IS WEAK..................................................................................................................................................570 H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY...............................................................................................................571 H-5 THE GEAR IS NOT SHIFTED......................................................................................................................................................572 H-6 THE STEERING WHEEL DOES NOT TURN.............................................................................................................................................573 H-7 THE STEERING WHEEL IS HEAVY..................................................................................................................................................574 H-8 STEERING WHEEL SHAKES OR JERKS...............................................................................................................................................575 H-9 MACHINE DEVIATES NATURALLY TO ONE SIDE WHEN TRAVELING........................................................................................................................575 H-10 THE BRAKE DOES NOT WORK OR DOES NOT WORK WELL...............................................................................................................................576 H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED.....................................................................................................................................577 H-12 THE LIFT ARM DOES NOT RISE OR LOWER.........................................................................................................................................578 H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT......................................................................................................579 H-14 WHEN RISING, THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT...........................................................................................................580 H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKT (THE BUCKET RISES IN THE AIR)..............................................................................................580 H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN................................................................................................................................580 H-17 THE LIFT ARM WOBBLES DURING OPERATION.......................................................................................................................................580 H-18 WHEN THE CONTROL LEVER IS SWITCHED FROM "HOLD" TO "RAISE," THE LIFT ARM FALLS TEMPORARILY..................................................................................581 H-19 THE BUCKET DOES OT TILT BACK................................................................................................................................................582 H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT...........................................................................................................583 H-21 THE BUCKET COMES TO OPERATE SLOWLY IN THE MIDST OF TILTINGBACK..............................................................................................................584 H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET.............................................................................................................................584 H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN..................................................................................................................................584 H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO "HOLD").....................................................................................585 H-25 WHEN THE CONTROL LEVEL IS SWITCHED FROM "HOLD" TO "TILT," THE BUCKET FALLS TEMPRARILY.......................................................................................585 H-26 THE CONTROL LEVERS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY................................................................................................585 H-27 TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES..............................................................................................................586 TROUBLESHOOTING OF ENGINE (S MODE)...................................................................................................................................................587 METHOD OF USING TROUBLESHOOTING CHARTS...........................................................................................................................................588 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)....................................................................................................................592 S-2 ENGINE DOES NOT START........................................................................................................................................................594 (1) ENGINE DOES NOT TURN.....................................................................................................................................................594 (2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).................................................................................................595 (3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...............................................................................................596 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).........................................................................................................................597 S-4 ENGINE STOPS DURING OPERATIONS...............................................................................................................................................598 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)....................................................................................................................................599 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER).........................................................................................................................................600 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)...............................................................................................................................601 S-8 OIL CONSUMPTION IS EXCESSIVE.................................................................................................................................................602 S-9 OIL BECOMES CONTAMINATED QUICKLY.............................................................................................................................................603 S-10 FUEL CONSUMPTION IS EXCESSIVE...............................................................................................................................................604 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.....................................................................................................605 S-12 OIL PRESSURE CAUTION LAMP LIGHT UP (DROP IN OIL PRESSURE)...................................................................................................................606 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)........................................................................................................................................607 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................................................................................................608 S-15 ABNORMAL NOISE IS MADE......................................................................................................................................................609 S-16 VIBRATION IS EXCESSIVE......................................................................................................................................................610 30 DISASSEMBLY AND ASSEMBLY..................................................................................................................................................................611 HOW TO READ THIS MANUAL..................................................................................................................................................................612 PRECAUTIONS WHEN CARRYING OUT OPERATION..................................................................................................................................................614 SPECIAL TOOL LIST........................................................................................................................................................................616 SKETCH OF SPECIAL TOOLS..................................................................................................................................................................619 REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY....................................................................................................................................625 REMOVAL, INSTALLATION OF NOZZLE HOLDER ASSEMBLY..........................................................................................................................................629 REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY..........................................................................................................................................631 REMOVAL, INSTALLATION OF ENGINE ASSEMBLY.................................................................................................................................................639 REMOVAL, INSTALLATION OF RADIATOR ASSEMBLY...............................................................................................................................................646 REMOVAL, INSTALLATION OF AIR AFTERCOOLER.................................................................................................................................................647 REMOVAL, INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...................................................................................................................................649 REMOVAL, INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY..............................................................................................................................651 REMOVAL, INSTALLATION OF FUEL TANK ASSEMBLY..............................................................................................................................................653 REMOVAL, INSTALLATION OF TRANSFER........................................................................................................................................................655 DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY...............................................................................................................................................657 REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY..........................................................................................................................................677 DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY..........................................................................................................................................679 REMOVAL, INSTALLATION OF FRONT AXLE ASSEMBLY.............................................................................................................................................684 REMOVAL, INSTALLATION OF REAR AXLE ASSEMBLY..............................................................................................................................................686 DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY...........................................................................................................................................689 DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY...........................................................................................................................................702 REMOVAL, INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY...............................................................................................................................726 REMOVAL, INSTALLATION OF HST MOTOR 1 ASSEMBLY............................................................................................................................................729 REMOVAL, INSTALLATION OF HST MOTOR 2 ASSEMBLY............................................................................................................................................731 REMOVAL, INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY...........................................................................................................................733 REMOVAL, INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY....................................................................................................................................735 REMOVAL, INSTALLATION OF HYDRAULIC TANK ASSEMBLY.........................................................................................................................................737 REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY.........................................................................................................................................739 DISASSEMBLY AND ASSEMBLYOF HST PUMP ASSEMBLY.............................................................................................................................................746 DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY...........................................................................................................................................773 DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.....................................................................................................................................789 REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY.........................................................................................................................................796 REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS)..............................................................................................................................802 REMOVAL, INSTALLATION OF CENTER HINGE PIN................................................................................................................................................810 REMOVAL, INSTALLATION OF COUNTERWEIGHT...................................................................................................................................................821 REMOVAL, INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...................................................................................................................................823 REMOVAL, INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY.............................................................................................................................826 REMOVAL, INSTALLATION OF MONITOR PANEL...................................................................................................................................................827 REMOVAL, INSTALLATION OF HST CONTROLLER ASSEMBLY.........................................................................................................................................831 90 OTHERS....................................................................................................................................................................................832 HYDRAULIC CIRCUIT DIAGRAM................................................................................................................................................................833 ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4).....................................................................................................................................................834 ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4).....................................................................................................................................................835 ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4).....................................................................................................................................................836 ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4).....................................................................................................................................................837 ELECTRICAL CIRCUIT DIAGRAM 2/4...........................................................................................................................................................838 ELECTRICAL CIRCUIT DIAGRAM 3/4...........................................................................................................................................................839 ELECTRICAL CIRCUIT DIAGRAM 4/4...........................................................................................................................................................840 ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)1/2..................................................................................................................................................841 ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)2/2..................................................................................................................................................842 CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE).......................................................................................................................................843
DESCRIPTION:
KOMATSU WA320-5 WA320L-5 WHEEL LOADER SHOP MANUAL – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
S.S 29/12/24
