Komatsu WA320-3 Wheel Loader Shop Manual CEBMW19071 PDF
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Komatsu WA320-3 Wheel Loader Shop Manual CEBMW19071 – PDF DOWNLOAD
SERIAL NUMBERS WA320-3LE – A30001 and up
Description
Komatsu WA320-3 Wheel Loader Shop Manual CEBMW19071 – PDF DOWNLOAD
FILE DETAILS:
Komatsu WA320-3 Wheel Loader Shop Manual CEBMW19071 – PDF DOWNLOAD
Language : English
Pages : 669
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu WA320-3 Wheel Loader Shop Manual CEBMW19071 – PDF DOWNLOAD
SERIAL NUMBERS WA320-3LE – A30001 and up
GENERAL PRECAUTIONS :
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
PREPARATIONS FOR WORK:
PRECAUTIONS DURING WORK :
TABLE OF CONTENTS:
Komatsu WA320-3 Wheel Loader Shop Manual CEBMW19071 – PDF DOWNLOAD
SERIAL NUMBERS WA320-3LE – A30001 and up
MAIN MENU 0
CONTENTS 2
01 GENERAL 24
SPECIFICATION DRAWINGS 25
SPECIFICATIONS 26
WEIGHT TABLE 29
FUEL, COOLANT AND LUBRICANTS 30
ENGINE OIL SPECIFICATIONS 31
DIESEL FUEL SPECIFICATIONS 32
COOLANT SPECIFICATIONS 33
10 STRUCTURE AND FUNCTION 38
POWER TRAIN 39
POWER TRAIN SYSTEM 40
TORQUE CONVERTER, TRANSMISSION PIPING 42
TRANSMISSION HYDRAULIC SYSTEM DIAGRAM 43
TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM 44
TORQUE CONVERTER 45
TORQUE CONVERTER OIL FILTER 47
TRANSMISSION 48
TRANSMISSION CONTROL VALVE 59
DRIVE SHAFT 81
AXLE 82
DIFFERENTIAL 84
FINAL DRIVE 88
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 110
ACCUMULATOR CHARGE VALVE 115
ACCUMULATOR (FOR BRAKE) 119
BRAKE 121
PARKING BRAKE CONTROL 124
PARKING BRAKE 125
PARKING BRAKE SOLENOID VALVE 126
PARKING BRAKE VALVE 127
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE 128
HYDRAULIC PIPING 129
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM 131
WORK EQUIPEMENT HYDRAULIC CIRCUIT DIAGRAM 132
WORK EQUIPMENT LEVER LINKAGE 134
HYDRAULIC TANK 135
PPC VALVE 137
PPC RELIEF VALVE 142
ACCUMULATOR (FOR PPC VALVE) 143
MAIN CONTROL VALVE 144
WORK EQUIPMENT LINKAGE 159
BUCKET 161
BUCKET POSITIONER AND BOOM KICK-OUT 162
CAB 168
AIR CONDITIONER 169
ELECTRIC CIRCUIT DIAGRAM 170
MACHINE MONITOR SYSTEM 175
MAIN MONITOR 176
MAINTENANCE MONITOR 180
E C S S (ELECTRONICALLY CONTROL SUSPENSION SYSTEM) 182
SENSORS 186
ENGINE STARTING CIRCUIT 190
ENGINE STOP CIRCUIT 191
ETHER START CIRCUIT 192
ELECTRIC TRANSMISSION CONTROL 193
KICK-DOWN SWITCH 196
KICK-DOWN ELECTRIC CIRCUIT DIAGRAM 197
TRANSMISSION CUT-OFF SWITCH 202
TRANSMISSION CUT-OFF FUNCTION 203
ELECTRIC PARKING BRAKE CONTROL 205
20 STRUCTURE AND FUNCTION 217
STANDARD VALUE TABLE FOR ENGINE 218
STANDARD VALUE TABLE FOR CHASSIS 219
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 223
SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING 227
MEASURING ENGINE SPEEDS 228
MEASURING INTAKE MANIFOLD PRESSURE 228
MEASURING INTAKE AIR RESTRICTION 228
MEASURING ENGINE LUBRICATING OIL PRESSURE 229
MEASURING FUEL FILTER INLET RESTRICTION 229
MEASURING BLOW-BY PRESSURE 229
MEASURING EXHAUST BACK PRESSURE 230
MEASURING EXHAUST GAS COLOR 231
MEASURING COOLANT TEMPERATURE 232
MEASURING AND ADJUSTING VALVE CLEARANCE 232
MEASURING WASTEGATE ACTUATOR 232
MEASURING STALL SPEEDS 233
MEASURING ACCELERATOR PEDAL 235
MEASURING OPERATING FORCE & TRAVEL OF DIRECTIONAL & SPEED LEVERS 237
MEASURING TORQUE CONVERTER, TRANSMISSION, PARKING BRAKE OIL PRESSURE 238
METHOD OF OPERATING EMERGENCY MANUAL SPOOL 240
MEASURING CLEARANCE BETWEEN TIRE AND WHEEL 242
TESTING AND ADJUSTING STEERING WHEEL 243
MEASURING STEERING OIL PRESSURE 245
MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL 247
MEASURING BRAKE PERFORMANCE 248
TESTING BRAKE OIL PRESSURE 249
TESTING FOR BRAKE DISC WEAR 250
BLEEDING AIR FROM BRAKE SYSTEM 251
MEASURING PARKING BRAKE PERFORMANCE 252
MANUAL RELEASE METHOD FOR PARKING BRAKE 253
TESTING WEAR OF PARKING BRAKE DISC 254
MEASURING WORK EQUIPMENT CONTROL LEVER 255
MEASURING WORK EQUIPMENT HYDRAULIC PRESURE 257
MEASURING PPC VALVE PRESSURE 259
MEASURING WORK EQUIPMENT 261
TESTING AND ADJUSTING BUCKET POSITIONER 263
TESTING AND ADJUSTING BOOM KICK-OUT 264
ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE) 266
TROUBLESHOOTING 267
POINTS TO REMEMBER WHEN TROUBLESHOOTING 268
SEQUENCE OF EVENTS IN TROUBLESHOOTING 269
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 270
HANDLING CONNECTORS 277
CHECKS BEFORE TROUBLESHOOTING 278
METHOD OF USING TROUBLESHOOTING CHARTS 279
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 287
S-1 Starting performance is poor (Staring always takes time) 288
S-2 Engine does not start 289
(1) Engine does not turn 289
(2) Engine turns but no exhaust gas comes out (Fuel is not being injected) 290
(3) Exhaust gas comes out but engine does not start (Fuel is being injected) 291
S-3 Engine does not pick up smoothly (Follow-up is poor) 292
S-4 Engine stops during operations 293
S-5 Engine does not rotate smoothly (hunting) 294
S-6 Engine lacks output (no power) 295
S-7 Exhaust gas is black (incomplete combustion) 296
S-8 Oil consumption is excessive (or exhaust gas is blue) 297
S-9 Oil becomes contaminated quickly 298
S-I0 Fuel consumption is excessive 299
S-11 Oil is in cooling water, or water spurts back, or water level goes down 300
S-12 Oil pressure lamp lights up (drop in oil pressure) 301
S-13 Oil level rises 302
S-14 Water temperature becomes too high (overheating) 303
S-15 Abnormal noise is made 304
S-16 Vibration is excessive 305
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE) 306
TROUBLE DATA DISPLAY 308
M-1 Main monitor does not work 310
M-2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up 311
M-3 Speedometer display does not work properly 312
M-4 Abnormality in shift indicator 313
(a) Stays at N even when directional lever is at F 313
(b) Stays at N even when directional lever is at R 313
(c) Does not display N even when directional lever is at N and displays R when directional lever is at F 313
(d) Does not display N even when directional lever is at N and displays F when directional lever is at R 314
(e) Does not display 1st, 4th 314
(f) Does not display 3rd, 4th 314
(g) Does not display 2nd, 3rd 315
(h) Does not display 1st, 2nd 315
M-5 High beam does not light up 316
M-6 Turn signal display does not light up 317
(a) L H turn signal does not light up 317
(b) R H turn signal does not light up 317
M-7 Abnormality in parking display 318
(a) Parking lamp does not light up 318
(b) Parking lamp stays lighted up 318
M-8 NOT USED 0
M-9 Night lighting does not light up 319
M-10 Abnormality in front working lamp 320
(a) Neither monitor display nor front working lamp light up 320
(b) Working lamp lights up but monitor display does not light up 320
(c)Monitor lights up but working lamp does not light up 320
M-11 Abnormality in rear working lamp 321
(a) Neither monitor display nor rear working lamp light up 321
(b) Working lamp lights up but monitor display does not light up 321
(c) Monitor lights up but working lamp does not light up 321
M-12 Abnormality in transmission cut-off 323
(a) When monitor switch is pressed, cut-off function is not switched and display is not given 323
(b) Monitor display goes out but cut-off function stays on 323
(c) Monitor display lights up but cut-off function is not actuated 324
M-13 Abnormality in parking brake dragging warning 325
(a) When parking brake is applied, buzzer sounds (intermittenly) even when directional lever is at N, and caution lamp flashes 325
(b) When parking brake is applied, buzzer does not sound and caution lamp does not light up even when directional lever is at po 325
M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not adjusted 326
(a) Actuated continuously 326
(b) Not actuated 326
M-15 Abnormality in buzzer 327
(a) Buzzer does not sound when starting switch is turned ON (during self-check) 327
(b) Buzzer always sounds 327
M-16 Condition of monitor switches is not stored in memory 328
M-17 Abnormality in failure display mode 329
(a) Does not enter failure display mode 329
(b) Time for time elapsed since failure on failure display mode does not advance 329
M-18 Abnormality in emergency steering normal display 330
(a) Emergency steering normal display does not light up 330
(b) Emergency steering normal display stays lighted up 330
M-19 Abnormality in emergency steering actuation display 331
(a) Emergency steering actuation display does not light up 331
(b) Emergency steering actuation display stays lighted up 331
M-20 Abnormality in auto-greasing system 332
(a) Forced greasing cannot be carried out 332
(b) Monitor display flashes rapidly (2 times/sec) 332
(c) When no more grease remains, monitor display flashes rapidly (2 times/sec) 332
(d) Monitor display flashes slowly (1 time/sec) 333
(e) Monitor display goes out 333
M-21 Abnormality in ECSS system 334
(a) Display does not change when switch is pressed 334
(b) Monitor display lights up but ECSS function does not work 334
M-22 Buzzer does not sound when auto-leveling switch is actuated 334
M-23 Failure code is not sent to main monitor (abnormality in network) 335
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE) 336
K-1 When starting switch is turned ON, all lamps on maintenance monitor do not light up for 3 sec , does not work 337
(a) All lamps on maintenance monitor do not light up for 3 seconds 337
(b) Some lamps do not light up 338
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out 338
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 339
K-4 When starting switch is turned ON (engine stopped), CHECK items 340
(a) Engine oil level display flashes 340
(b) Engine water level display flashes 341
K-5 When starting switch is turned ON (engine started), CAUTION items flash 342
(a) Engine oil pressure display flashes 342
(b) Battery charge level display flashes 343
(c) Brake oil pressure display flashes 344
(d) Air cleaner display flashes 345
K-6 CAUTION items are flashing but alarm buzzer does not sound 346
K-7 There is no abnormality in monitor display but alarm buzzer sounds 347
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not light up 348
(a) CHECK lamp 348
(b) CAUTION lamp 348
K-9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up 349
(a) CHECK lamp 349
(b) CAUTION lamp 349
K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up) 350
K-11 Night lighting does not light up even when lamp switch is OFF, night lighting stays lighted up 351
K-12 Service meter does not work 352
K-13 Service meter is running even when engine is stopped 352
K-14 Abnormality in gauge items 353
(a) Abnormality in torque converter oil temperature gauge 353
(b) Abnormality in engine water temperature gauge 354
(c) Abnormality in torque converter oil temperature gauge 355
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 356
E-1 Engine does not start 357
(a) Starting motor does not turn 357
(b) Starting motor turns 361
E-2 Engine does not stop 363
E-3 Engine stops when machine is traveling 363
E-4 Parking brake does not work 364
(a) Parking brake has no effect when parking brake switch is turned ON (parking) 364
(b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake) 364
E-5 Parking brake is applied when machine is traveling 365
E-6 Parking brake is released when starting switch is turned ON 367
E-7 Transmission does not change to neutral when parking brake is applied (but parking brake works normally) 367
E-8 Transmission does not work normally 368
(a) Problem in common circuit for transmission (always stays in 2nd) 370
(b) Problem in H-L circuit 370
(c) Problem in speed circuit 371
(d) Problem in 4th circuit (does not enter 4th) 371
(e) Contact in H-L circuit 372
(f) Contact in speed circuit 374
(g) Contact in 4th circuit (always stays in 4th) 376
(h) Problem in FORWARD circuit (REVERSE is normal) 377
(i) Problem in REVERSE circuit (FORWARD is normal) 379
(j) Problem in common circuit for FORWARD and REVERSE (does not travel forward, parking brake is normal) 381
(k) Contact in FORWARD circuit 383
(I) Contact in REVERSE circuit 385
(m) Problem in common circuit for FORWARD and REVERSE 387
E-9 Kick-down switch does not work (the regular Fl to F4 shifts normally) 388
E-10 Kick-down works only when kick-down switch is ON (Kick-down switch relay does not hold in position (self-holding feature) 390
E-11 Kick-down operation cannot be canceled 390
(a) Not canceled even when directional lever is moved from F to N or R 390
(b) Not canceled even when speed lever is moved from 2nd to other position (becomes 4th) 391
E-12 Kick-down switch is actuated by mistake when traveling in 2nd 393
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE) 394
POWER TRAIN 395
T-1 Machine does not start 395
T-2 Travel speed is slow, thrusting power is weak, lacks power on slopes 397
T-3 Excessive shock when starting machine or shifting gear 399
T-4 Excessive time lag when starting machine or shifting gear 400
T-5 Torque converter oil temperature is high 401
STEERING SYSTEM 402
T-6 Steering does not turn 402
T-7 Steering wheel is heavy 403
T-8 Steering wheel wobbles or there is excessive shock 404
T-9 Machine steers to one side when traveling 404
T-10 Turning radius to left and right is different 404
BRAKE SYSTEM 405
T-11 Brakes do not work or braking effect is poor 405
T-12 Brakes are not released or brakes drag 406
T-13 Parking brake is not released or brake drags 407
WORK EQUIPMENT 408
T-14 Boom does not rise 408
T-15 Boom movement is slow or boom lacks lifting power 409
T-16 When boom is raised, it moves slowly at a certain height 410
T-17 Bucket cannot be pushed with boom cylinder (bucket floats) 410
T-18 Excessive hydraulic drift of boom 410
T-19 Boom shakes during operation 410
T-20 Boom drops momentarily when control lever is operated from HOLD to RAISE 411
T-21 Bucket does not tilt back 412
T-22 Bucket movement is slow or tilt-back lacks power 413
T-23 Bucket movement during tilt-back operation 414
T-24 Bucket cannot be pushed with bucket cylinder 414
T-25 Excessive hydraulic drift of bucket 414
T-26 Bucket shakes during loading operation (Main control valve at HOLD) 415
T-27 Bucket dumps momentarily when control lever is operated from HOLD to TILT 415
T-28 Boom, bucket control levers are heavy or do not move smoothly 416
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE) 417
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM 418
D-1 ECSS does not work 419
(a) Error code [d0] is displayed 420
(b) Error code [d1] is displayed 420
(c) Error code [d2] is displayed 421
(d) Error code [d3] is displayed 421
(e) Error code [d4] is displayed 422
(f) No abnormality display is given 422
D-2 ECSS cannot be canceled 426
D-3 Output is turned ON (travel speed does not become 5 km/h) (deviates around 5 km/h) 427
D-4 Output is turned ON when transmission is in 1st 427
D-5 Output is turned ON when transmission is in 4th 428
D-6 Controller LED code is not displayed 429
D-7 ECSS is abnormal but main monitor does not give abnormality display 429
TROUBLESHOOTING – EAGLE AIR CONDITIONER 430
30 DISASSEMBLY AND ASSEMBLY 434
METHOD OF USING MANUAL 436
PRECAUTIONS WHEN CARRYING OUT OPERATION 437
SPECIAL TOOL LIST 439
SKETCHES OF SPECIAL TOOLS 441
TORQUE CONVERTER CHARGING PUMP 442
TORQUE CONVERTER 442
DISASSEMBLY 443
ASSEMBLY 445
TRANSMISSION 447
DISASSEMBLY 447
ASSEMBLY 457
TRANSMISSION CLUTCH PACK 471
DISASSEMBLY 471
ASSEMBLY 477
TRANSMISSION CONTROL VALVE 489
REMOVAL 489
INSTALLATION 491
DISASSEMBLY 492
ASSEMBLY 494
TRANSMISSION ACCUMULATOR VALVE 497
DISASSEMBLY 497
ASSEMBLY 498
TRANSMISSION MODULATING VALVE 499
DISASSEMBLY 499
ASSEMBLY 500
DRIVE SHAFT 501
DISASSEMBLY 501
ASSEMBLY 503
FRONT AXLE 505
REMOVAL 505
INSTALLATION 507
REAR AXLE 508
REMOVAL 508
INSTALLATION 512
DIFFERENTIAL 513
DISASSEMBLY 513
ASSEMBLY 518
AXLE HOUSING 528
DISASSEMBLY 528
ASSEMBLY 534
CENTER HINGE PIN 543
REMOVAL 543
INSTALLATION 548
PRIORITY VALVE 552
REMOVAL 552
INSTALLATION 553
STEERING VALVE 554
REMOVAL 554
INSTALLATION 555
DISASSEMBLY 556
ASSEMBLY 559
STEERING CYLINDER 564
REMOVAL 564
INSTALLATION 565
RIGHT BRAKE VALVE (TANDEM) 566
DISASSEMBLY 566
ASSEMBLY 567
LEFT BRAKE VALVE (SINGLE) 568
DISASSEMBLY 568
ASSEMBLY 569
PARKING BRAKE DISC 570
REMOVAL 570
INSTALLATION 572
HYDRAULIC TANK 573
REMOVAL 573
INSTALLATION 574
HYDRAULIC FILTER 575
HYDRAULIC STEERING PUMP 576
REMOVAL 576
INSTALLATION 582
MAIN CONTROL VALVE 583
REMOVAL 583
INSTALLATION 584
DISASSEMBLY 585
ASSEMBLY 587
3-SPOOL CONTROL VALVE 590
DISASSEMBLY 590
ASSEMBLY 592
PPC VALVE 595
REMOVAL 595
INSTALLATION 596
DISASSEMBLY 597
ASSEMBLY 598
BUCKET CYLINDER 599
REMOVAL 599
INSTALLATION 600
BOOM CYLINDER 601
REMOVAL 601
INSTALLATION 602
HYDRAULIC CYLINDER 603
DISASSEMBLY 603
ASSEMBLY 606
WORK EQUIPMENT 609
REMOVAL 609
INSTALLATION 612
COUNTERWEIGHT 614
REMOVAL AND INSTALLATION 614
CAB 615
REMOVAL 615
INSTALLATION 617
MAIN MONITOR 619
REMOVAL 619
INSTALLATION 620
MAINTENANCE MONITOR 621
REMOVAL AND INSTALLATION 621
40 MAINTENANCE STANDARD 622
ENGINE MOUNT, TRANSMISSION MOUNT 623
TORQUE CONVERTER CHARGING PUMP 624
TORQUE CONVERTER 625
TRANSMISSION 626
TRANSMISSION CONTROL VALVE 635
MODULATION VALVE ASSEMBLY 639
ACCUMULATOR VALVE 640
DRIVE SHAFT 641
DIFFERENTIAL 642
FINAL DRIVE 645
AXLE MOUNT 647
CENTER HINGE PIN 648
STEERING COLUMN 650
PRIORITY VALVE 651
STEERING CYLINDER MOUNT 652
BRAKE 653
BRAKE VALVE 654
PARKING BRAKE 657
HYDRAULIC PUMP 658
MAIN CONTROL VALVE 659
PPC VALVE 663
HYDRAULIC CYLINDER 664
WORK EQUIPMENT LINKAGE 665
BUCKET 667
BUCKET POSITIONER AND BOOM KICK-OUT 668
S.V 15/12/24
