Komatsu WA320-3 Avance Loader Shop Manual SEBM006006 – PDF DOWNLOAD

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Komatsu WA320-3 Avance Loader Shop Manual SEBM006006 – PDF DOWNLOAD

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Komatsu WA320-3 Avance Loader Shop Manual SEBM006006 – PDF DOWNLOAD

Language : English
Pages : 845
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu WA320-3 Avance Loader Shop Manual SEBM006006 – PDF DOWNLOAD

COVER 1
CONTENTS 2
01 GENERAL 24
GENERAL ASSEMBLY DRAWING 25
SPECIFICATIONS 27
WEIGHT TABLE 30
LIST OF LUBRICANT AND WATER 32
10 STRUCTURE AND FUNCTION 34
POWER TRAIN 35
POWER TRAIN SYSTEM 36
TORQUE CONVERTER, TRANSMISSION PIPING 38
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 39
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 40
TORQUE CONVERTER 41
TORQUE CONVERTER OIL FILTER 43
TRANSMISSION 44
TRANSMISSION CONTROL VALVE 54
DRIVE SHAFT 76
AXLE 77
DIFFERENTIAL 81
FINAL DRIVE 87
AXLE MOUNT, CENTER HINGE PIN 89
STEERING PIPING 91
STEERING COLUMN 92
PRIORITY VALVE 93
STEERING VALVE (ORBIT-ROLL) 98
CUSHION VALVE 106
2-WAY RESTRICTOR VALVE 107
BRAKE PIPING 108
BRAKE HYDRAULIC CIRCUIT DIAGRAM 109
BRAKE VALVE 111
ACCUMULATOR CHARGE VALVE 116
ACCUMULATOR (FOR BRAKE) 122
BRAKE 124
PARKING BRAKE CONTROL 129
PARKING BRAKE 130
PARKING BRAKE SOLENOID VALVE 131
PARKING BRAKE VALVE 132
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE 133
HYDRAULIC PIPING 134
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM 135
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 136
WORK EQUIPMENT LEVER LINKAGE 140
HYDRAULIC TANK 141
PPC VALVE 143
PPC RELIEF VALVE 148
ACCUMULATOR (FOR PPC VALVE) 149
MAIN CONTROL VALVE 150
WORK EQUIPMENT LINKAGE 165
BUCKET 167
BUCKET POSITIONER AND BOOM KICK-OUT 168
CAB 174
ROPS CAB 176
AIR CONDITIONER 177
ELECTRIC CIRCUIT DIAGRAM 178
MACHINE MONITOR SYSTEM 193
MAIN MONITOR 194
MAINTENANCE MONITOR 199
TRANSMISSION AUTO-SHIFT CONTROL SYSTEM 202
WORK EQUIPMENT CONTROL SYSTEM 210
E C S S (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) 217
SENSORS 221
ENGINE STARTING CIRCUIT 225
ENGINE STOP CIRCUIT 226
PREHEATING CIRCUIT 227
ELECTRIC TRANSMISSION CONTROL 228
KICK-DOWN, HOLD SWITCH 231
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM 232
TRANSMISSION CUT-OFF SWITCH 241
TRANSMISSION CUT-OFF FUNCTION 242
ELECTRIC PARKING BRAKE CONTROL 246
20 TESTING AND ADJUSTING 259
STANDARD VALUE TABLE FOR ENGINE 260
STANDARD VALUE TABLE FOR CHASSIS 261
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 265
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 269
ADJUSTING VALVE CLEARANCE 270
MEASURING COMPRESSION PRESSURE 271
MEASURING BLOW-BY PRESSURE 272
TESTING AND ADJUSTING FUEL INJECTION TIMING 273
MEASURING EXHAUST COLOR 275
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 276
MEASURING EXHAUST GAS TEMPERATURE 277
MEASURING ENGINE OIL PRESSURE 278
MEASURING ENGINE SPEED 279
TESTING AND ADJUSTING FAN BELT TENSION 280
METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE 281
MEASURING ACCELERATOR PEDAL 283
MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER 285
MEASURING STALL SPEED 286
MEASURING TORQUE CONVERTER, TRANSMISSION,PARKING BRAKE OIL PRESSURE 288
METHOD OF OPERATING EMERGENCY MANUAL SPOOL 290
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL 292
TESTING AND ADJUSTING STEERING WHEEL 293
MEASURING STEERING OIL PRESSURE 295
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL 297
MEASURING BRAKE PERFORMANCE 298
TESTING BRAKE OIL PRESSURE 299
TESTING FOR BRAKE DISC WEAR 300
BLEEDING AIR FROM BRAKE SYSTEM 301
MEASURING PARKING BRAKE PERFORMANCE 302
MANUAL RELEASE METHOD FOR PARKING BRAKE 303
TESTING WEAR OF PARKING BRAKE DISC 304
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE 305
MEASURING WORK EQUIPMENT CONTROL LEVER 306
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE 308
MEASURING PPC VALVE PRESSURE 310
MEASURING WORK EQUIPMENT 312
TESTING AND ADJUSTING BUCKET POSITIONER 314
TESTING AND ADJUSTING BOOM KICK-OUT 315
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) 317
ADJUSTING BOOM, BUCKET ANGLE POTENTIOMETER 318
TROUBLESHOOTING 319
POINTS TO REMEMBER WHEN TROUBLESHOOTING 320
SEQUENCE OF EVENTS IN TROUBLESHOOTING 321
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 322
HANDLING CONNECTORS 329
CHECKS BEFORE TROUBLESHOOTING 330
METHOD OF USING TROUBLESHOOTING CHARTS 331
CONNECTOR TYPES AND MOUNTING LOCATIONS 339
CONNECTOR PIN ARRANGEMENT DIAGRAM 340
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 345
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 352
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 353
S-2 ENGINE DOES NOT START 354
(1) ENGINE DOES NOT TURN 354
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) 355
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 356
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 357
S-4 ENGINE STOPS DURING OPERATIONS 358
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 359
S-6 ENGINE LACKS OUTPUT (NO POWER) 360
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 361
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 362
S-9 OIL BECOMES CONTAMINATED QUICKLY 363
S-10 FUEL CONSUMPTION IS EXCESSIVE 364
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 365
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 366
S-13 OIL LEVEL RISES 367
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 368
S-15 ABNORMAL NOISE IS MADE 369
S-16 VIBRATION IS EXCESSIVE 370
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) 371
TROUBLE DATA DISPLAY 373
M-1 MAIN MONITOR DOES NOT WORK 375
M-2 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIGHTED UP 376
M-3 SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY 377
M-4 ABNORMALITY IN SHIFT INDICATOR 378
(a) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT F 378
(b) STAYS AT N EVEN WHEN DIRECTIONAL LEVER IS AT R 378
(c) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS R WHEN DIRECTIONAL LEVER IS AT F 378
(d) DOES NOT DISPLAY N EVEN WHEN DIRECTIONAL LEVER IS AT N AND DISPLAYS F WHEN DIRECTIONAL LEVER IS AT R 379
(e) DOES NOT DISPLAY 1ST, 4TH 379
(f) DOES NOT DISPLAY 3RD, 4TH 379
(g) DOES NOT DISPLAY 2ND, 3RD 380
(h) DOES NOT DISPLAY 1ST, 2ND 380
M-5 HIGH BEAM DOES NOT LIGHT UP 381
M-6 TURN SIGNAL DISPLAY DOES NOT LIGHT UP 382
(a) L H TURN SIGNAL DOES NOT LIGHT UP 382
(b) R H TURN SIGNAL DOES NOT LIGHT UP 382
M-7 ABNORMALITY IN PARKING DISPLAY 383
(a) PARKING LAMP DOES NOT LIGHT UP 383
(b) PARKING LAMP STAYS LIGHTED UP 383
M-8 ABNORMALITY IN PREHEATING SYSTEM (QGS) 384
(a) DOES NOT CARRY OUT PREHEATING 384
(b) ALWAYS CARRIES OUT PREHEATING FOR 1 MINUTE 385
(c) PREHEATING STAYS ON 385
(d) PREHEATING TIME BECOMES SHORTER, OR THERE IS VARIATION 386
M-9 NIGHT LIGHTING DOES NOT LIGHT UP 387
M-10 ABNORMALITY IN FRONT WORKING LAMP 388
(a) NEITHER MONITOR DISPLAY NOR FRONT WORKING LAMP LIGHT UP 388
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 388
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP 388
M-11 ABNORMALITY IN REAR WORKING LAMP 389
(a) NEITHER MONITOR DISPLAY NOR REAR WORKING LAMP LIGHT UP 389
(b) WORKING LAMP LIGHTS UP BUT MONITOR DISPLAY DOES NOT LIGHT UP 389
(c) MONITOR LIGHTS UP BUT WORKING LAMP DOES NOT LIGHT UP 389
M-12 ABNORMALITY IN TRANSMISSION CUT-OFF 391
(a) WHEN MONITOR SWITCH IS PRESSED, CUT-OFF FUNCTION IS NOT SWITCHED AND DISPLAY IS NOT GIVEN 391
(b) MONITOR DISPLAY GOES OUT BUT CUT-OFF FUNCTION STAYS ON 391
(c) MONITOR DISPLAY LIGHTS UP BUT CUT-OFF FUNCTION IS NOT ACTUATED 392
M-13 ABNORMALITY IN PARKING BRAKE DRAGGING WARNING 393
(a) WHEN PARKING BRAKE IS APPLIED, BUZZER SOUNDS (INTERMITTENTLY) EVEN WHEN DIRECTIONAL LEVER IS AT N, AND CAUTION LAMP FLASHES 393
(b) WHEN PARKING BRAKE IS APPLIED, BUZZER DOES NOT SOUND AND CAUTION LAMP DOES NOT LIGHT UP EVEN WHEN DIRECTIONAL LEVER IS AT POSITION OTHER THAN N 393
M-14 WHEN PARKING BRAKE DRAGGING WARNING IS GIVEN, BUZZER AND CAUTION LAMP ARE ACTUATED CONTINUOUSLY, OR THEY ARE NOT ACTUATED 394
(a) ACTUATED CONTINUOUSLY 394
(b) NOT ACTUATED 394
M-15 ABNORMALITY IN BUZZER 395
(a) BUZZER DOES NOT SOUND WHEN STARTING SWITCH IS TURNED ON (DURING SELF-CHECK) 395
(b) BUZZER ALWAYS SOUNDS 395
M-16 CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY 396
M-17 ABNORMALITY IN FAILURE DISPLAY MODE 397
(a) DOES NOT ENTER FAILURE DISPLAY MODE 397
(b) TIMES FOR TIME ELAPSED SINCE FAILURE ON FAILURE DISPLAY MODE DOES NOT ADVANCE 397
M-18 ABNORMALITY IN EMERGENCY STEERING NORMAL DISPLAY 398
(a) EMERGENCY STEERING NORMAL DISPLAY DOES NOT LIGHT UP 398
(b) EMERGENCY STEERING NORMAL DISPLAY LIGHTED UP 398
M-19 ABNORMALITY IN EMERGENCY STEERING ACTUATION DISPLAY 399
(a) EMERGENCY STEERING ACTUATION DISPLAY DOES NOT LIGHT UP 399
(b) EMERGENCY STEERING ACTUATION DISPLAY STAYS LIGHTED UP 399
M-20 ABNORMALITY IN AUTO-GREASING SYSTEM 400
(a) FORCED GREASING CANNOT BE CARRIED OUT 400
(b) MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC) 400
(c) WHEN NO MORE GREASE REMAINS, MONITOR DISPLAY FLASHES RAPIDLY (2 TIMES/SEC) 400
(d) MONITOR DISPLAY FLASHES SLOWLY (1 TIME/SEC) 401
(e) MONITOR DISPLAY GOES OUT 401
M-21 ABNORMALITY IN ECSS SYSTEM 402
(a) DISPLAY DOES NOT CHANGE WHEN SWITCH IS PRESSED 402
(b) MONITOR DISPLAY LIGHTS UP BUT ECSS FUNCTION DOES NOT WORK 402
M-22 BUZZER DOES NOT SOUND WHEN AUTO-LEVELING SWITCH IS ACTUATED 402
M-23 FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK) 403
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) 404
K-1 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR DOES NOT WORK 405
(a) ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS 405
(b) SOME LAMPS DO NOT LIGHT UP 406
K-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR LIGHT UP BUT DO NOT GO OUT 406
K-3 WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON (WITHIN 3 SECONDS), ALL LAMPS ON MAINTENANCE MONITOR DO NOT GO OUT 407
K-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH 408
(a) ENGINE OIL LEVEL DISPLAY FLASHES 408
(b) ENGINE WATER LEVEL DISPLAY FLASHES 409
K-5 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH 410
(a) ENGINE OIL PRESSURE DISPLAY FLASHES 410
(b) BATTERY CHARGE LEVEL DISPLAY FLASHES 411
(c) BRAKE OIL PRESSURE DISPLAY FLASHES 412
(d) AIR CLEANER DISPLAY FLASHES 413
K-6 CAUTION ITEMS ARE FLASHING BUT ALARM BUZZER DOES NOT SOUND 414
K-7 THERE IS NO ABNORMALITY IN MONITOR DISPLAY BUT ALARM BUZZER SOUNDS 415
K-8 CAUTION ITEMS ARE FLASHING BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT LIGHT UP 416
(a) CHECK LAMP 416
(b) CAUTION LAMP 416
K-9 THERE IS NO ABNORMALITY IN MAINTENANCE MONITOR DISPLAY BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) LIGHTS UP 417
(a) CHECK LAMP 417
(b) CAUTION LAMP 417
K-10 NIGHT LIGHTING DOES NOT LIGHT UP WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT LIGHT UP) 418
K-11 NIGHT LIGHTING LIGHTS UP EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS LIGHTED UP 419
K-12 SERVICE METER DOES NOT WORK 420
K-13 SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED 420
K-14 ABNORMALITY IN GAUGE ITEMS 421
(a) ABNORMALITY IN FUEL GAUGE 421
(b) ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE 422
(c) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE 423
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 424
E-1 ENGINE DOES NOT START 425
(a) STARTING MOTOR DOES NOT TURN 425
(b) STARTING MOTOR TURNS 429
E-2 ENGINE DOES NOT STOP 431
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING 431
E-4 PARKING BRAKE DOES NOT WORK 432
(a) PARKING BRAKE HAS NO EFFECT WHEN PARKING BRAKE SWITCH IS TURNED ON (PARKING) 432
(b) PARKING BRAKE HAS NO EFFECT WHEN BRAKE PRESSURE DROPS (DOES NOT WORK AS EMERGENCY BRAKE) 432
E-5 PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING 433
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON 435
E-7 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (WITHOUT AUTO-SIFT TRANSMISSION) 435
E-8 TRANSMISSION DOES NOT WORK NORMALLY (WITHOUT AUTO-SIFT TRANSMISSION) 436
(a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION (ALWAYS STAYS IN 2ND) 438
(b) PROBLEM IN H-L CIRCUIT 438
(c) PROBLEM IN SPEED CIRCUIT 439
(d) PROBLEM IN 4TH CIRCUIT (DOES NOT ENTER 4TH) 439
(e) CONTACT IN H-L CIRCUIT 440
(f) CONTACT IN SPEED CIRCUIT 442
(g) CONTACT IN 4TH CIRCUIT (ALWAYS STAYS IN 4TH) 444
(h) PROBLEM IN FORWARD CIRCUIT (REVERSE IS NORMAL) 445
(i) PROBLEM IN REVERSE CIRCUIT (FORWARD IS NORMAL) 447
(j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE (DOES NOT TRAVEL FORWARD, PARKING BRAKE IS NORMAL) 449
(k) CONTACT IN FORWARD CIRCUIT 451
(l) CONTACT IN REVERSE CIRCUIT 453
(m) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE 455
E-9 KICK-DOWN SWITCH DOES NOT WORK (WITHOUT AUTO-SIFT TRANSMISSION) (THE REGULAR F1 TO F4 SHIFTS NORMALLY) 456
E-10 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT HOLD IN POSITION (SELF-HOLDING FUNCTION))(WITHOUT AUTO-SIFT TRANSMISSION) 458
E-11 KICK-DOWN OPERATION CANNOT BE CANCELED (WITHOUT AUTO-SIFT TRANSMISSION) 458
(a) NOT CANCELED EVEN WHEN DIRECTIONAL LEVER IS MOVED FROM F TO N OR R 458
(b) NOT CANCELED EVEN WHEN SPEED LEVER IS MOVED FROM 2ND TO OTHER POSITION (BECOMES 4TH) 459
E-12 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND (WITHOUT AUTO-SIFT TRANSMISSION) 461
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED)(T MODE) 462
POWER TRAIN 463
T-1 MACHINE DOES NOT START 463
T-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES 465
T-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR 467
T-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 468
T-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH 469
STEERING SYSTEM 470
T-6 STEERING WHEEL DOES NOT TURN 470
T-7 STEERING IS HEAVY 471
T-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK 472
BRAKE SYSTEM 473
T-9 BRAKE DO NOT WORK OR BRAKING EFFECT IS POOR 473
T-10 BRAKES ARE NOT RELEASED OR BRAKES DRAG 474
T-11 PARKING BRAKE IS NOT RELEASED OR BRAKE DRAGS 475
WORK EQUIPMENT 476
T-12 BOOM DOES NOT RISE 476
T-13 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER 477
T-14 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT 478
T-15 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS) 478
T-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM 478
T-17 BOOM SHAKES DURING OPERATION 478
T-18 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE 479
T-19 BUCKET DOES NOT TILT BACK 480
T-20 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER 481
T-21 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION 482
T-22 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER 482
T-23 EXCESSIVE HYDRAULIC DRIFT OF BUCKET 482
T-24 BUCKET SHAKES DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD) 483
T-25 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT 483
T-26 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY 484
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM)(D MODE) 485
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM) 486
D-1 ECSS DOES NOT WORK 487
(a) ERROR CODE [d0] IS DISPLAYED 488
(b) ERROR CODE [d1] IS DISPLAYED 488
(c) ERROR CODE [d2] IS DISPLAYED 489
(d) ERROR CODE [d3] IS DISPLAYED 489
(e) ERROR CODE [d4] IS DISPLAYED 490
(f) NO ABNORMALITY DISPLAY IS GIVEN 490
D-2 ECSS CANNOT BE CANCELED 494
D-3 OUTPUT IS TURNED ON (TRAVEL SPEED DOES NOT BECOME 5 KM/H)(DEVIATES AROUND 5 KM/H) 495
D-4 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST 495
D-5 OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH 496
D-6 CONTROLLER LED CODE IS NOT DISPLAYED 497
D-7 ECSS IS ABNORMAL BUT MAIN MONITOR DOES NOT GIVE ABNORMALITY DISPLAY 497
TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYSTEM (W MODE) 498
OUTLINE 500
1 FUNCTION 500
2 WHEN CARRYING OUT TROUBLESHOOTING 500
3 FAILURE CODE TABLE 500
4 TABEL OF TROUBLESHOOTING MODES AND CAUSES 501
W-1 FAILURE CODE [40] ABNORMALITY IN BUCKET DUMP SOLENOID SYSTEM 503
W-2 FAILURE CODE [41] SHORT CIRCUIT IN POWER SOURCE WHEN BUCKET DUMP, TILT SOLENOIDS ARE OFF 504
W-3 FAILURE CODE [42] ABNORMALITY IN BUCKET TILT SOLENOID SYSTEM 505
W-4 FAILURE CODE [43] ABNORMALITY IN DAMPING SOLENOID SYSTEM 506
W-5 FAILURE CODE [44] SHORT CIRCUIT IN POWER SOURCE AT HOT END OF DAMPING SOLENOID 507
W-6 FAILURE CODE [45] SHORT CIRCUIT IN POWER SOURCE AT RETURN END OF DAMPING SOLENOID 507
W-7 FAILURE CODE [48] ANMORMALITY IN BUCKET LEVER KICK-OUT RELAY SYSTEM 508
W-8 FAILURE CODE [49] ABNORMALITY IN BOOM LEVER KICK-OUT RELAY SYSTEM 510
W-9 FAILURE CODE [50] ABNORMALITY IN AUTO-LEVELER RELAY SYSTEM 511
W-10 FAILURE CODE [51] DISCONNECTION IN BOOM RAISE, LOWER DETECTION PRESSURE SWITCH 512
W-11 FAILURE CODE [52] ABNORMALITY IN BOOM ANGLE POTENTIONMETER SYSTEM 513
W-12 FAILURE CODE [53] ABNORMALITY IN BUCKET ANGLE POTENTIOMETER SYSTEM 513
W-13 FAILURE CODE [54] ABNORMALITY IN MODEL SELECTION WIRING HARNESS 515
W-14 SENSOR CANNOT BE ADJUSTED 516
W-15 DOES NOT CARRY OUT AUTO-LEVELING 517
(a) AUTO-LEVELER SWITCH SYSTEM 517
(b) AUTO-LEVELER LED SYSTEM 517
(c) BUCKET LEVER NEUTRAL SWITCH SYSTEM 518
(d) ENGINE SPEED SIGNAL SYSTEM 519
W-16 AUTO-LEVELER CANNOT BE SET 520
(a) AUTO-LEVELER SET SWITCH SYSTEM 520
(b) AUTO-LEVELER SET LED SYSTEM 520
W-17 REMOTE POSITIONER RAISE, LOWER LEDS DO NOT LIGHT UP 521
(a) REMOTE POSITIONER SWITCH SYSTEM 521
(b) REMOTE POSITIONER LED SYSTEM 521
W-18 REMOTE POSITIONER SET LEDS DO NOT FLASH 522
(a) REMOTE POSITIONER SWITCH SYSTEM 522
(b) REMOTE POSITIONER LED SYSTEM 522
W-19 BUCKET DOES NOT TILT IMMEDIATELY AT BOOM FLOAT DETENT WHEN REMOTE POSITIONER IS AT RAISE AND AUTO MODE IS ON 523
W-20 BUZZER FOR SWITCH OPERATION DOES NOT SOUND 524
W-21 BUCKET CORRECTION, BOOM STOP RESPONSE ARE SLOW 525
W-22 BUCKET (LEVER) CONTROL 526
(a) BUCKET KICK-OUT DOES NOT WORK EVEN WHEN BUCKET IS AT MAXIMUM TILT 526
(b) LEVER IS NOT HELD BY DETENT 527
W-23 FAILURE CODE IS NOT DISPLAYED ON MAIN MONITOR 529
W-24 MAINTENANCE MONITOR CHECK 530
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (WITH AUTO-SIFT TRANSMISSION)(A MODE) 531
OUTLINE 532
1 FUNCTION 532
2 WHEN CARRYING OUT TROUBLESHOOTING 532
3 FAILURE CODE TABLE 532
4 ACTION CODE TABLE 533
5 TABLE OF TROUBLESHOOTING MODES AND CAUSES 534
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLER SYSTEM 535
A-1 TROUBLESHOOTING CODE [12] F SOLENOID SIGNAL SYSTEM 537
A-2 TROUBLESHOOTING CODE [13] R SOLENOID SIGNAL SYSTEM 537
A-3 TROUBLESHOOTING CODE [14] ABNORMALITY IN H-L SOLENOID SIGNAL SYSTEM 538
A-4 TROUBLESHOOTING CODE [16] ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM 539
A-5 TROUBLESHOOTING CODE [20] ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM 540
A-6 TROUBLESHOOTING CODE [21] ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM 541
A-7 TROUBLESHOOTING CODE [22] ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM 542
A-8 TROUBLESHOOTING CODE [23] ABNORMALITY IN ENGINE SPEED SIGNAL 543
A-9 HOLD SWITCH SYSTEM 544
A-10 KICK-DOWN SWITCH SYSTEM 544
A-11 TRANSMISSION CUT-OFF SIGNAL SYSTEM 545
A-12 NEUTRALIZER RELAY SIGNAL SYSTEM 546
A-13 BUZZER SIGNAL SYSTEM 547
A-14 NETWORK SIGNAL SYSTEM 548
A-15 CONTROLLER POWER SOURCE SYSTEM 549
30 DISASSEMBLY AND ASSEMBLY 550
METHOD OF USING MANUAL 552
PRECAUTIONS WHEN CARRYING OUT OPERATION 553
SPECIAL TOOL LIST 555
SKETCHES OF SPECIAL TOOLS 557
STARTING MOTOR 558
REMOVAL AND INSTALLATION 558
ALTERNATOR 559
REMOVAL AND INSTALLATION 559
ENGINE OIL COOLER 560
REMOVAL AND INSTALLATION 560
FUEL INJECTION PUMP 561
REMOVAL 561
INSTALLATION 562
WATER PUMP 563
REMOVAL AND INSTALLATION 563
TURBOCHARGER 565
REMOVAL AND INSTALLATION 565
NOZZLE HOLDER 566
REMOVAL AND INSTALLATION 566
THERMOSTAT 567
REMOVAL AND INSTALLATION 567
CYLINDER HEAD 568
REMOVAL 568
INSTALLATION 573
RADIATOR 575
REMOVAL 575
INSTALLATION 580
ENGINE 581
REMOVAL 581
INSTALLATION 585
TORQUE CONVERTER CHARGING PUMP 586
REMOVAL AND INSTALLATION 586
TORQUE CONVERTER, TRANSMISSION 587
REMOVAL 587
INSTALLATION 600
TORQUE CONVERTER 603
DISASSEMBLY 603
ASSEMBLY 605
TRANSMISSION 607
DISASSEMBLY 607
ASSEMBLY 617
TRANSMISSION CLUTCH PACK 631
DISASSEMBLY 631
ASSEMBLY 637
TRANSMISSION CONTROL VALVE 649
REMOVAL 649
INSTALLATION 651
DISASSEMBLY 652
ASSEMBLY 654
TRANSMISSION ACCUMULATOR VALVE 657
DISASSEMBLY 657
ASSEMBLY 658
TRANSMISSION MODULATING VALVE 659
DISASSEMBLY 659
ASSEMBLY 660
DRIVE SHAFT 661
DISASSEMBLY 661
ASSEMBLY 663
FRONT AXLE 665
REMOVAL 665
INSTALLATION 667
REAR AXLE 668
REMOVAL 668
INSTALLATION 672
DIFFERENTIAL 673
DISASSEMBLY 673
ASSEMBLY 678
AXLE HOUSING 688
DISASSEMBLY 688
ASSEMBLY 694
CENTER HINGE PIN 703
REMOVAL 703
INSTALLATION 708
PRIORITY VALVE 712
REMOVAL 712
INSTALLATION 713
STEERING VALVE 714
REMOVAL 714
INSTALLATION 715
DISASSEMBLY 716
ASSEMBLY 719
STEERING CYLINDER 724
REMOVAL 724
INSTALLATION 725
RIGHT BRAKE VALVE (TANDEM) 726
DISASSEMBLY 726
ASSEMBLY 727
LEFT BRAKE VALVE (SINGLE) 728
DISASSEMBLY 728
ASSEMBLY 729
PARKING BRAKE DISC 730
REMOVAL 730
INSTALLATION 732
ACCUMULATOR CHARGE VALVE 733
REMOVAL 733
INSTALLATION 733
DISASSEMBLY 734
ASSEMBLY 736
HYDRAULIC TANK 738
REMOVAL 738
INSTALLATION 739
HYDRAULIC FILTER 740
REMOVAL AND INSTALLATION 740
HYDRAULIC, STEERING PUMP 741
REMOVAL 741
INSTALLATION 747
MAIN CONTROL VALVE 748
REMOVAL 748
INSTALLATION 749
DISASSEMBLY 750
ASSEMBLY 752
PPC VALVE 755
REMOVAL 755
INSTALLATION 756
DISASSEMBLY 757
ASSEMBLY 758
BUCKET CYLINDER 759
REMOVAL 759
INSTALLATION 760
BOOM CYLINDER 761
REMOVAL 761
INSTALLATION 762
HYDRAULIC CYLINDER 763
DISASSEMBLY 763
ASSEMBLY 766
WORK EQUIPMENT 769
REMOVAL 769
INSTALLATION 772
COUNTERWEIGHT 774
REMOVAL AND INSTALLATION 774
FUEL TANK 775
REMOVAL 775
INSTALLATION 777
CAB 778
REMOVAL 778
INSTALLATION 779
MAIN MONITOR 780
REMOVAL 780
INSTALLATION 781
MAINTENANCE MONITOR 782
REMOVAL AND INSTALLATION 782
AIR CONDITIONER UNIT 783
REMOVAL 783
INSTALLATION 788
AIR CONDITIONER CONDENSER 789
REMOVAL 789
INSTALLATION 790
DRY RECEIVER 791
REMOVAL AND INSTALLATION 791
AIR CONDITIONER COMPRESSOR 792
REMOVAL 792
INSTALLATION 793
40 MAINTENANCE STANDARD 794
ENGINE MOUNT, TRANSMISSION MOUNT 795
TORQUE CONVERTER CHARGING PUMP 796
TORQUE CONVERTER 797
TRANSMISSION 798
TRANSMISSION CONTROL VALVE 806
MODULATION VALVE ASSEMBLY 810
ACCUMULATOR VALVE 811
DRIVE SHAFT 812
DIFFERENTIAL 813
FINAL DRIVE 819
AXLE MOUNT 823
CENTER HINGE PIN 824
STEERING COLUMN 826
PRIORITY VALVE 827
STEERING CYLINDER MOUNT 828
BRAKE 829
BRAKE VALVE 831
PARKING BRAKE 834
HYDRAULIC PUMP 835
MAIN CONTROL VALVE 836
PPC VALVE 840
HYDRAULIC CYLINDER 841
WORK EQUIPMENT LINKAGE 842
BUCKET 844
BUCKET POSITIONER AND BOOM KICK-OUT 845

DESCRIPTION:

Komatsu WA320-3 Avance Loader Shop Manual SEBM006006 – PDF DOWNLOAD

FOREWORD
This shop manual has been prepared as an aid in improving 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 availably opportunity.
Organization
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 chapters for each main group of components; these chapters are further divided into the following sections.
Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
Testing and adjusting
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Diagnoses” to “Causes” are also included in this section.
Disassembly and assembly
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
Maintenance standards
This section gives the judgement standards when inspecting disassembled parts.

G.B  14/12/24