Komatsu WA320-1LC Wheel Loader Shop Manual CEBMW19020 PDF

Description

Komatsu WA320-1LC Wheel Loader Shop Manual CEBMW19020 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA320-1LC Wheel Loader Shop Manual CEBMW19020 – PDF DOWNLOAD 

Language : English
Pages : 640
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu WA320-1LC Wheel Loader Shop Manual CEBMW19020 – PDF DOWNLOAD 

MACHINE MODEL          SERIAL NUMBERS
WA320-1LC                          A25001 and up

TABLE OF CONTENTS:

Komatsu WA320-1LC Wheel Loader Shop Manual CEBMW19020 – PDF DOWNLOAD

MACHINE MODEL          SERIAL NUMBERS
WA320-1LC                          A25001 and up

MAIN MENU 0
CONTENTS 7
10 ENGINE 21
12 TESTING AND ADJUSTING 21
STANDARD VALUE TABLE 22
TOOL LIST FOR TESTING AND ADJUSTING 25
VALVE CLEARANCE 27
FUEL INJECTION TIMING 28
ENGINE OIL PRESSURE AND TEMPERATURE 29
BLOW-BY PRESSURE 31
EXHAUST GAS COLOR 32
ACCELERATOR PEDAL, OPERATING FORCE AND OPERATING ANGLE 33
13 DISASSEMBLY AND ASSEMBLY 37
STARTING MOTOR 39
REMOVAL 39
INSTALLATION 39
ALTERNATOR 40
REMOVAL 40
INSTALLATION 40
OIL COOLER 41
REMOVAL 41
INSTALLATION 41
FUEL INJECTION PUMP 42
REMOVAL 42
INSTALLATION 42
WATER PUMP 43
REMOVAL 43
INSTALLATION 43
INJECTORS 44
REMOVAL 44
INSTALLATION 45
TURBOCHARGER 46
REMOVAL 46
INSTALLATION 47
CYLINDER HEAD 48
REMOVAL 48
INSTALLATION 49
RADIATOR 50
REMOVAL 50
INSTALLATION 52
ENGINE 54
REMOVAL 54
INSTALLATION 59
FUEL TANK 64
REMOVAL 64
INSTALLATION 65
14 MAINTENANCE STANDARD 67
ENGINE MOUNT 68
RADIATOR AND TORQUE CONVERTER OIL COOLER 69
20 POWER TRAIN 71
21 STRUCTURE AND FUNCTION 71
GENERAL 72
HYDRAULIC CIRCUIT FOR POWER TRAIN 76
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 77
TORQUE CONVERTER AND TRANSMISSION PIPING 78
TORQUE CONVERTER CHARGING PUMP 79
TORQUE CONVERTER 80
TORQUE CONVERTER OIL FILTER 81
TRANSMISSION 82
CLUTCH PACK 84
FORWARD AND REVERSE CLUTCH 84
1ST, 3RD CLUTCH 84
2ND, 4TH CLUTCH 85
CONTROL VALVE 86
SOLENOID VALVE 87
UPPER VALVE 88
LOWER VALVE 89
PRIORITY AND MAIN REGULATOR VALVE 90
MAIN REGULATOR VALVE 91
TORQUE CONVERTER OIL OUTLET VALVE 92
PILOT REDUCING VALVE 93
SOLENOID VALVE 94
FILL VALVE 95
MODULATING RELIEF VALVE, ACCUMULATOR VALVE, QUICK RETURN VALVE 97
DIRECTIONAL SPOOL 101
EMERGENCY MANUAL SPOOL 102
PILOT OIL FILTER 103
AXLE MOUNT 104
AXLE 106
FRONT 106
REAR 107
DIFFERENTIAL 108
FINAL DRIVE 109
TIRE AND WHEEL 110
22 TESTING AND ADJUSTING 111
STANDARD VALUE TABLE 112
TOOL LIST FOR TESTING AND ADJUSTING 113
ENGINE STALL SPEED 114
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION 116
SHIFT LEVER 119
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL 120
TIRE AND WHEEL 122
TROUBLESHOOTING 123
PRECAUTIONS WHEN TROUBLESHOOTING 124
METHOD OF READING TROUBLESHOOTING TABLES 126
PREVENTING RECURRENCE OF TROUBLE 128
CHECKS BEFORE TROUBLESHOOTING 129
JUDGEMENT ON POWER TRAIN 130
TROUBLESHOOTING TABLE 132
1 Machine does not move 132
2 Machine speed is low, thrust is weak, gradeability falls off 134
3 Large shock when moving off or changing gear 136
4 Large time lag when moving off or changing gear 137
5 Oil temperature in torque converter is high 138
23 DISASSEMBLY AND ASSEMBLY 139
TORQUE CONVERTER CHARGING PUMP 141
REMOVAL 141
INSTALLATION 141
TRANSMISSION, TORQUE CONVERTER 142
REMOVAL 142
INSTALLATION 148
TORQUE CONVERTER 154
DISASSEMBLY 154
ASSEMBLY 157
TRANSMISSION 160
DISASSEMBLY 160
ASSEMBLY 167
CLUTCH PACK 178
DISASSEMBLY 178
FORWARD-REVERSE CLUTCH PACK 178
1ST-3RD SPEED CLUTCH PACK 180
2ND-4TH SPEED CLUTCH PACK 182
ASSEMBLY 184
FORWARD-REVERSE CLUTCH PACK 185
1ST-3RD SPEED CLUTCH PACK 190
2ND-4TH SPEED CLUTCH PACK 194
TRANSMISSION CONTROL VALVE 198
REMOVAL 198
INSTALLATION 199
TRANSMISSION SOLENOID VALVE 205
DISASSEMBLY 205
ASSEMBLY 205
DIFFERENTIAL 206
DISASSEMBLY 206
ASSEMBLY 210
FRONT AXLE 221
REMOVAL 221
INSTALLATlON 223
REAR AXLE 225
REMOVAL 225
INSTALLATION 228
DRIVE SHAFT 231
DISASSEMBLY 231
ASSEMBLY 233
AXLE HOUSING 235
DISASSEMBLY 235
ASSEMBLY 240
24 MAINTENANCE STANDARD 247
ENGINE AND TRANSMISSION MOUNT 248
TORQUE CONVERTER CHARGING PUMP 250
TORQUE CONVERTER 251
TRANSMISSION 252
TRANSMISSION CONTROL VALVE 255
UPPER VALVE 255
LOWER VALVE 257
SOLENOID VALVE 258
TRANSMISSION CLUTCH 259
DIFFERENTIAL 262
FINAL DRIVE 264
DRIVE SHAFT 266
AXLE MOUNT 267
AXLE 269
40 STEERING SYSTEM 273
41 STRUCTURE AND FUNCTION 273
HYDRAULIC PIPING 274
HYDRAULIC CIRCUIT SCHEMATICS 274
HYDRAULIC CIRCUIT DIAGRAM 276
2-SPOOL 276
3-SPOOL (WITH GROUND STEERING) DRJEN 277
3-SPOOL (WITH GROUND DRIVEN STEERING, SECURITY VALVE) 278
STEERING CONTROL SYSTEM 279
STEERING VALVE (ORBITROL VALVE) 279
PRIORITY VALVE 286
HAND PUMP AND SLEEVE 289
CUSHION VALVE 291
GROUND DRIVEN STEERING PUMP 292
DIVERTER VALVE 293
STEERING COLUMN 296
STEERING CYLINDER MOUNT AND CENTER HINGE PIN 297
42 TESTING AND ADJUSTING 299
STANDARD VALUE TABLE FOR CHASSIS 300
TOOL LIST 300
STEERING WHEEL 301
PLAY 301
OPERATING FORCE 302
OPERATING TIME – LOCK TO LOCK 303
STEERING OIL PRESSURE 304
TROUBLESHOOTING 305
STEERING SYSTEM 306
1 Steering wheel does not turn 306
2 Steering wheel is sluggish 307
3 Steering wheel moves unsteadily or is subjected to large shock 308
43 DISASSEMBLY AND ASSEMBLY 309
STEERING VALVE 310
REMOVAL 310
INSTALLATION 312
DISASSEMBLY 315
ASSEMBLY 318
PRIORITY VALVE 323
REMOVAL 323
INSTALLATION 325
STEERING CYLINDER 327
REMOVAL 327
INSTALLATION 328
DISASSEMBLY 329
ASSEMBLY 331
CENTER HINGE PIN 334
REMOVAL 334
INSTALLATlON 339
44 MAINTENANCE STANDARD 345
STEERING COLUMN 346
STEERING CYLINDER MOUNT 347
CENTER HINGE PIN 347
STEERING PUMP 350
PRIORITY VALVE 351
GROUND DRIVEN STEERING 352
50 BRAKE SYSTEM 353
51 STRUCTURE AND FUNCTION 353
BRAKE CONTROL SYSTEM 354
SYSTEM DIAGRAM 354
BRAKE CIRCUIT DIAGRAM 355
BRAKE CIRCUIT SCHEMATICS 356
CHARGE VALVE 357
ACCUMULATOR 361
BRAKE VALVE 362
PRESSURE CONTROL VALVE 363
SAFETY VALVE 364
BRAKE 365
PARKING BRAKE 366
BRAKE CALIPER 367
52 TESTING AND ADJUSTING 369
STANDARD VALUE TABLE 370
TOOL LIST 371
BRAKE PEDAL 372
BRAKE PEDAL LINKAGE 373
BRAKE PERFORMANCE 374
BRAKE PISTON LEAKAGE 375
BRAKE DISC 376
AIR BLEEDING 377
ACCUMULATOR CIRCUIT 377
FRONT AXLE BRAKE CIRCUIT 378
REAR AXLE BRAKE CIRCUIT 378
PARKING BRAKE 379
PERFORMANCE 379
CHECKING AND ADJUSTING 380
CLEARANCE 382
53 DISASSEMBLY AND ASSEMBLY 383
BRAKE VALVE 384
REMOVAL 384
INSTALLATION 385
DISASSEMBLY 386
ASSEMBLY 387
PARKING BRAKE 388
REMOVAL 388
INSTALLATION 390
PARKING BRAKE PAD 392
REMOVAL 392
INSTALLATION 392
ACCUMULATOR 393
REMOVAL 393
INSTALLATION 393
DISASSEMBLY 394
ASSEMBLY 394
54 MAINTENANCE STANDARD 397
BRAKE 398
PARKING BRAKE 399
BRAKE VALVE 400
60 WORK EQUIPMENT SYSTEM 401
61 STRUCTURE AND FUNCTION 401
HYDRAULIC PIPING 402
HYDRAULIC CIRCUIT DIAGRAMS 403
HYDRAULIC TANK 405
OIL FILTER BYPASS VALVE 406
BREATHER 407
HYDRAULIC AND STEERING PUMPS 408
HYDRAULIC VALVES 409
SECURITY VALVE 409
PRIORITY VALVE 410
RELIEF VALVE 411
SAFETY VALVE (WITH SUCTION VALVE) 412
SUCTION VALVE 413
MAIN CONTROL VALVE 414
2-SPOOL 414
3-SPOOL 416
OPERATION 418
HYDRAULIC CYLINDER 424
LIFT CYLINDER 424
DUMP CYLINDER 424
STEERING CYLINDER 424
BUCKET LINKAGE 425
WORK EQUIPMENT LEVER LINKAGE 427
62 TESTING AND ADJUSTING 429
STANDARD VALUE TABLE 431
TOOL LIST 432
DUMP AND LIFT CONTROL LEVERS 433
HYDRAULIC CIRCUIT FLUSHING 435
HYDRAULIC PRESSURE 438
LIFT ARM AND BUCKET 440
HYDRAULIC DRIFT OF LIFT ARM AND BUCKET 442
BUCKET POSITIONER 443
BOOM KICK-OUT 445
TROUBLESHOOTING 447
TROUBLESHOOTING TABLES 448
1 Lift arm does not rise 448
2 Lift arm moves slowly or does not have sufficient lifting power 449
3 Lift arm movement becomes slow after it reaches a certain height 450
4 Bucket cannot be held down with lift arm cylinder 450
5 Lift arm has large hydraulic drift 450
6 Lift arm movement is unsteady during work 450
7 Lift arm descends momentarily when control lever is shifted from “Hold” to “Raise” 450
8 Bucket does not tilt back 451
9 Bucket moves slowly or has insufficient tilt back power 452
10 Bucket movement becomes slow during tilt back 453
11 Bucket cannot be held down by the dump cylinder 453
12 Bucket has large hydraulic drift 453
13 Bucket moves unsteadily when machine travels under load (Main control valve in “Hold”) 453
14 Bucket dumps momentarily when control lever is shifted from “Hold” to “Tilt back” 453
15 Control levers of lift arm and bucket move stiffly and sluggishly 454
63 DISASSEMBLY AND ASSEMBLY 455
HYDRAULIC TANK 456
REMOVAL 456
INSTALLATION 459
HYDRAULIC FILTER 461
REMOVAL 461
INSTALLATION 461
HYDRAULIC & STEERING PUMP 462
REMOVAL 462
INSTALLATION 463
MAIN CONTROL VALVE 464
REMOVAL 464
INSTALLATION 466
DISASSEMBLY 467
ASSEMBLY 469
DUMP CYLINDER 471
REMOVAL 471
INSTALLATION 473
LlFT CYLINDER 474
REMOVAL 474
INSTALLATION 475
HYDRAULIC CYLINDER 476
DISASSEMBLY 476
ASSEMBLY 478
WORK EQUIPMENT 481
REMOVAL 481
INSTALLATION 484
COUNTERWEIGHT 487
REMOVAL 487
INSTALLATION 487
64 MAINTENANCE STANDARD 489
HYDRAULIC AND STEERING PUMPS 490
GROUND DRIVEN STEERING PUMP 491
PRIORITY VALVE 492
MAIN CONTROL VALVE 494
2-SPOOL 494
3-SPOOL 496
CYLINDER 498
STEERING CYLINDER 498
LIFT CYLINDER 498
DUMP CYLINDER 498
BUCKET LINKAGE 500
BUCKET 504
WITH TOOTH 504
WITH B O C 504
BUCKET POSITIONER AND BOOM KICK-OUT 505
80 ELECTRIC AND ELECTRONIC SYSTEM 507
81 STRUCTURE AND FUNCTION 507
ELECTRICAL FOLDOUT 508
ENGINE STARTING CIRCUIT 509
SAFETY RELAY 510
ENGINE STOP CIRCUIT 511
ELECTRICAL TRANSMISSION CONTROL 512
COMBINATION SWITCH 513
TRANSMISSION CUT-OFF SELECTOR SWITCH 514
NEUTRALIZER RELAY 515
KICK-DOWN SWITCH 516
KICK-DOWN ELECTRICAL CIRCUIT 517
BUCKET POSITIONER AND BOOM KICK-OUT 525
PROXIMITY SWITCH 527
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) 531
MONITOR PANEL 532
INDICATION ON MONITOR PANEL 533
SENSORS, SWITCHES 535
SENSOR, SWITCH ACTUATION TABLE 535
BRAKE PRESSURE SWITCH 536
BRAKE DIFFERENTIAL PRESSURE WARNING SWITCH 536
COOLANT LEVEL SENSOR 537
TORQUE CONVERTER OIL TEMPERATURE SENSOR 537
ROTATIONAL SPEED SENSOR 538
FUEL LEVEL SENSOR 539
82 TESTING AND ADJUSTING 541
SPEEDOMETER MODULE 543
TROUBLESHOOTING 545
PRECAUTION WHEN HANDLING CONNECTOR 546
CONNECTOR TERMINAL NUMBERS 548
POSITION OF CONNECTORS FOR TROUBLESHOOTING 553
ELECTRICAL CIRCUIT SYSTEM 558
ENGINE STARTING CIRCUIT SYSTEM 558
ENGINE STOP CIRCUIT SYSTEM 559
TRANSMISSION CONTROL AND PARKING BRAKE SYSTEM 560
ELECTRICAL CN AND THREE DIMENSIONAL VIEW DIAGRAM 561
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART 562
TROUBLESHOOTING TABLES 565
E-1 ENGINE DOES NOT START 566
E-2 ENGINE DOES NOT STOP 567
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING 567
E-4 TRANSMISSION DOES NOT RETURN TO NEUTRAL 568
E-5 TRANSMISSION DOES NOT WORK NORMALLY 569
E-6 KICK-DOWN SWITCH DOES NOT WORK 588
E-7 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON 590
E-8 KICK-DOWN OPERATION IS NOT CANCELED 591
E-9 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2 592
83 DISASSEMBLY AND ASSEMBLY 593
MACHINE MONITOR 594
REMOVAL 594
INSTALLATION 595
90 OTHER 597
93 DISASSEMBLY AND ASSEMBLY 597
CAB 598
REMOVAL 598
INSTALLATION 598
CAB 599
97 GEAR PUMP 601
GENERAL 602
PRINCIPLE OF OPERATION 603
PRESSURE LOADED TYPE GEAR PUMP 606
FIXED SIDE PLATE NPE GEAR PUMP 608
SA SERIES 609
STRUCTURE 609
TESTING AND ADJUSTING 613
DISASSEMBLY 616
ASSEMBLY 620
MAINTENANCE STANDARD 625
99 METRIC CONVERSIONS 627

S.V 14/12/24