KOMATSU WA320-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A31001 and up) KOMATSU WA320-3MC – PDF DOWNLOAD

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KOMATSU WA320-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A31001 and up) KOMATSU WA320-3MC

KOMATSU WA320-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A31001 AND UP) KOMATSU WA320-3MC – PDF DOWNLOAD:

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KOMATSU WA320-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A31001 and up) KOMATSU WA320-3MC

• 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 sections. These sections are further divided into each main group of components.
• GENERAL
  This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
• 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 “Problems” 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 STANDARD
  This section gives the judgement standards when inspecting disassembled parts.

TABLE OF CONTENTS:

KOMATSU WA320-3MC WHEEL LOADER SERVICE REPAIR MANUAL (SN:A31001 and up) KOMATSU WA320-3MC

MAIN MENU....................................................................................................................................  0
COVER........................................................................................................................................  1
CONTENTS.....................................................................................................................................  2
SAFETY.......................................................................................................................................  8
FORWORD...................................................................................................................................... 10
	HOW TO READ THE SHOP MANUAL.............................................................................................................. 11
	HOISTING INSTRUCTIONS.................................................................................................................... 12
	COATING MATERIALS........................................................................................................................ 13
	STANDARD TORQUE REQUIREMENTS............................................................................................................. 14
	ELECTRIC WIRE CODE....................................................................................................................... 16
	CONVERSION TABLES........................................................................................................................ 17
01 GENERAL................................................................................................................................... 24
	SPECIFICATIONS 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.................................................................................................................... 40
	POWER TRAIN.............................................................................................................................. 42
	POWER TRAIN SYSTEM....................................................................................................................... 43
	TORQUE CONVERTER, TRANSMISSION PIPING.................................................................................................... 45
	TRANSMISSION HYDRAULIC SYSTEM DIAGRAM.................................................................................................... 47
	TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM................................................................................................... 48
	TORQUE CONVERTER......................................................................................................................... 49
	TORQUE CONVERTER OIL FILTER.............................................................................................................. 51
	TRANSMISSION............................................................................................................................. 52
		CLUTCH............................................................................................................................... 55
		FORWARD 1ST.......................................................................................................................... 58
		FORWARD 2ND.......................................................................................................................... 59
		FORWARD 3RD.......................................................................................................................... 60
		FORWARD 4TH.......................................................................................................................... 61
		REVERSE 1ST.......................................................................................................................... 62
	TRANSMISSION CONTROL VALVE............................................................................................................... 63
		UPPER VALVE.......................................................................................................................... 64
		LOWER VALVE.......................................................................................................................... 65
	TRANSMISSION SOLENOID VALVE.............................................................................................................. 66
	PILOT REDUCING VALVE..................................................................................................................... 67
	MAIN RELIEF VALVE........................................................................................................................ 68
	TORQUE CONVERTER OUTLET PORT VALVE....................................................................................................... 69
	PRIORITY VALVE........................................................................................................................... 70
	QUICK RETURN VALVE....................................................................................................................... 71
	DIRECTIONAL SELECTOR VALVE............................................................................................................... 75
	H-L SELECTOR VALVE AND RANGE SELECTOR VALVE.............................................................................................. 76
	EMERGENCY MANUAL SPOOL................................................................................................................... 78
	MODULATION VALVE......................................................................................................................... 79
	ACCUMULATOR VALVE........................................................................................................................ 82
	PILOT OIL FILTER......................................................................................................................... 84
	DRIVE SHAFT.............................................................................................................................. 85
	AXLE..................................................................................................................................... 86
		FRONT AXLE........................................................................................................................... 86
		REAR AXLE............................................................................................................................ 87
	DIFFERENTIAL............................................................................................................................. 88
		FRONT DIFFERENTIAL................................................................................................................... 88
		REAR DIFFERENTIAL.................................................................................................................... 89
		TORQUE PROPORTIONING DIFFERENTIAL.................................................................................................... 91
		LIMITED SLIP DIFFERENTIAL............................................................................................................ 92
	FINAL DRIVE.............................................................................................................................. 96
	AXLE MOUNT, CENTER HINGE PIN............................................................................................................. 97
	STEERING PIPING.......................................................................................................................... 99
	STEERING COLUMN..........................................................................................................................100
	PRIORITY VALVE...........................................................................................................................101
	STEERING VALVE (ORBIT-ROLL)..............................................................................................................106
	CONNECTION BETWEEN HAND PUMP AND SLEEVE..................................................................................................113
	CUSHION VALVE............................................................................................................................115
	2-WAY RESTRICTOR VALVE...................................................................................................................116
	BRAKE PIPING.............................................................................................................................117
	BRAKE HYDRAULIC CIRCUIT DIAGRAM..........................................................................................................118
	BRAKE VALVE..............................................................................................................................119
		RIGHT................................................................................................................................119
		LEFT.................................................................................................................................120
	ACCUMULATOR CHARGE VALVE.................................................................................................................124
	ACCUMULATOR (FOR BRAKE)..................................................................................................................128
	BRAKE....................................................................................................................................129
		FRONT BRAKE..........................................................................................................................129
		REAR BRAKE...........................................................................................................................130
	PARKING BRAKE CONTROL....................................................................................................................132
	PARKING BRAKE............................................................................................................................133
	PARKING BRAKE SOLENOID VALVE.............................................................................................................134
	PARKING BRAKE VALVE......................................................................................................................135
	PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE...........................................................................................136
	HYDRAULIC PIPING.........................................................................................................................138
	WORK EQUIPMENT LEVER LINKAGE.............................................................................................................142
	HYDRAULIC TANK...........................................................................................................................143
	PPC VALVE................................................................................................................................145
	PPC RELIEF VALVE.........................................................................................................................150
	ACCUMULATOR (FOR PPC VALVE)..............................................................................................................151
	MAIN CONTROL VALVE.......................................................................................................................153
		2-SPOOL..............................................................................................................................153
		3-SPOOL (OPTIONAL)...................................................................................................................155
	RELIEF VALVE.............................................................................................................................157
	SAFETY VALVE (WITH SUCTION)..............................................................................................................158
	SUCTION VALVE............................................................................................................................159
	MAIN CONTROL VALVE OPERATION.............................................................................................................162
	WORK EQUIPMENT LINKAGE...................................................................................................................169
	BUCKET...................................................................................................................................171
	BUCKET POSITIONER AND BOOM KICK-OUT......................................................................................................172
	ROPS CAB.................................................................................................................................178
	AIR CONDITIONER..........................................................................................................................179
	ELECTRIC CIRCUIT DIAGRAM.................................................................................................................184
	MACHINE MONITOR SYSTEM...................................................................................................................187
	MAIN MONITOR.............................................................................................................................188
		MAIN MONITOR DISPLAY FUNCTION........................................................................................................189
		MAIN MONITOR SWITCH FUNCTION.........................................................................................................190
	TROUBLE DATA DISPLAY MODE................................................................................................................191
	MAINTENANCE MONITOR......................................................................................................................192
		MAINTENANCE MONITOR DISPLAY FUNCTION.................................................................................................193
	TRANSMISSION AUTO-SHIFT CONTROL SYSTEM...................................................................................................194
		SHIFT CONTROL SYSTEM FUNCTION........................................................................................................195
		TRANSMISSION CONTROLLER..............................................................................................................200
		LED DISPLAY..........................................................................................................................201
	E.C.S.S. (ELECTRONICALLY CONTROL SUSPENSION SYSTEM)......................................................................................202
	SENSORS..................................................................................................................................206
		RADIATOR COOLANT LEVEL SENSORS.......................................................................................................207
		ENGINE COOLANT TEMPERATURE SENSOR....................................................................................................207
		TORQUE CONVERTER OIL TEMPERATURE SENSOR..............................................................................................207
		FUEL LEVEL SENSOR....................................................................................................................208
		ENGINE SPEED SENSOR..................................................................................................................209
		ENGINE OIL PRESSURE SENSOR...........................................................................................................209
	ENGINE STARTING CIRCUIT..................................................................................................................210
	ENGINE STOP CIRCUIT......................................................................................................................211
	ETHER START CIRCUIT......................................................................................................................212
	ELECTRIC TRANSMISSION CONTROL............................................................................................................213
	COMBINATION SWITCH.......................................................................................................................214
	KICK-DOWN, HOLD SWITCH...................................................................................................................216
	KICK-DOWN ELECTRIC CIRCUIT DIAGRAM.......................................................................................................217
		NORMAL OPERATION.....................................................................................................................217
		KICK-DOWN SWITCH OPERATED............................................................................................................218
		CANCELING ACTUATION OF KICK-DOWN SWITCH (CASE I).....................................................................................219
		CANCELING ACTUATION OF KICK-DOWN SWITCH (CASE II)....................................................................................220
	TRANSMISSION CUT-OFF SWITCH..............................................................................................................221
	TRANSMISSION CUT-OFF FUNCTION............................................................................................................222
	ELECTRIC PARKING BRAKE CONTROL...........................................................................................................224
		PARKING BRAKE EMERGENCY RELEASE SWITCH...............................................................................................226
		EMERGENCY BRAKE SWITCH...............................................................................................................226
		PARKING BRAKE SAFETY RELAY...........................................................................................................227
		NEUTRALIZER RELAY....................................................................................................................227
20 TESTING, ADJUSTING AND TROUBLESHOOTING....................................................................................................237
	STANDARD VALUE TABLE FOR ENGINE..........................................................................................................238
	STANDARD VALUE TABLE FOR CHASSIS.........................................................................................................239
	STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM...............................................................................................242
	SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING...................................................................................246
	MEASURING ENGINE SPEEDS..................................................................................................................247
	MEASURING INTAKE MANIFOLD PRESSURE.......................................................................................................247
	MEASURING INTAKE AIR RESTRICTION.........................................................................................................247
	MEASURING ENGINE LUBRICATING OIL PRESSURE................................................................................................248
	MEASURING FUEL FILTER INLET RESTRICTION..................................................................................................248
	MEASURING BLOW-BY PRESSURE...............................................................................................................248
	MEASURING EXHAUST BACK PRESSURE..........................................................................................................249
	MEASURING EXHAUST GAS COLOR..............................................................................................................250
	MEASURING COOLANT TEMPERATURE............................................................................................................251
	MEASURING AND ADJUSTING VALVE CLEARANCE..................................................................................................251
	MEASURING WASTEGATE ACTUATOR CALIBRATION.................................................................................................251
	MEASURING STALL SPEEDS...................................................................................................................252
		TORQUE CONVERTER STALL SPEED.........................................................................................................252
		HYDRAULIC STALL SPEED................................................................................................................253
		FULL STALL SPEED.....................................................................................................................253
	MEASURING ACCELERATOR PEDAL..............................................................................................................254
		OPERATING FORCE OF ACCELERATOR PEDAL.................................................................................................254
		OPERATING ANGLE OF ACCELERATOR PEDAL.................................................................................................255
	MEASURING OPERATING FORCE & TRAVEL OF DIRECTIONAL & SPEED LEVERS.........................................................................256
	MEASURING TORQUE CONVERTER, TRANSMISSION, AND PARKING BRAKE OIL PRESSURE.................................................................257
	METHOD OF OPERATING EMERGENCY MANUAL SPOOL...............................................................................................259
	MEASURING CLEARENCE BETWEEN TIRE AND WHEEL...............................................................................................261
	TESTING AND ADJUSTING STEERING WHEEL.....................................................................................................262
		MEASURING OPERATING FORCE OF STEERING WHEEL..........................................................................................262
		MEASURING OPERATING TIME FOR STEERING WHEEL..........................................................................................263
	MEASURING STEERING OIL PRESSURE..........................................................................................................264
	METHOD OF ADJUSTING MAIN RELIEF PRESSURE.................................................................................................265
	MEASURING OPERATING FORCE & TRAVEL OF BRAKE PEDAL........................................................................................266
	MEASURING BRAKE PERFORMANCE..............................................................................................................267
	TESTING BRAKE OIL PRESSURE...............................................................................................................268
	TESTING FOR BRAKE DISC WEAR..............................................................................................................269
	BLEEDING AIR FROM BRAKE SYSTEM...........................................................................................................270
	MEASURING PARKING BRAKE PERFORMANCE......................................................................................................271
	MANUAL RELEASE METHOD FOR PARKING BRAKE..................................................................................................272
	TESTING WEAR OF PARKING BRAKE DISC.......................................................................................................273
	MEASURING WOIRK EQUIPMENT CONTROL LEVER..................................................................................................274
	MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE..............................................................................................276
	MEASURING PPC VALVE PRESSURE.............................................................................................................278
	MEASURING WORK EQUIPMENT.................................................................................................................280
	MEASURING WORK EQUIPMENT HYDRAULIC DRIFT.................................................................................................281
	TESTING AND ADJUSTING BUCKET POSITIONER..................................................................................................282
	TESTING AND ADJUSTING BOOM KICK-OUT......................................................................................................283
	ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)..............................................................................................285
	TROUBLESHOOTING..........................................................................................................................286
		POINTS TO REMEMBER WHEN TROUBLESHOOTING..............................................................................................287
		SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................................................288
		PRECAUTIONS WHEN CARRYING OUT MAINTENANCE............................................................................................289
		HANDLING CONNECTORS..................................................................................................................296
		CHECKS BEFORE TROUBLESHOOTING........................................................................................................297
		METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................299
		CONNECTOR TYPES AND MOUNTING LOCATIONS...............................................................................................307
		TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)............................................................................................313
			S-1  STARTING PERFORMANCE IS POOR, STARTING ALWAYS TAKES TIME....................................................................314
			S-2  ENGINE DOES NOT START.......................................................................................................315
			S-3  ENGINE DOES NOT PICK UP SMOOTHLY, FOLLOW UP IS POOR.........................................................................318
			S-4  ENGINE STOPS DURING OPERATIONS..............................................................................................319
			S-5  ENGINE DOES NOT RUN SMOOTHLY, HUNTING.......................................................................................320
			S-6  ENGINE LACKS OUTPUT, NO POWER...............................................................................................321
			S-7  ENGINE SMOKE IS BLACK, INCOMPLETE COMBUSTION................................................................................322
			S-8  OIL CONSUMPTION IS EXCESSIVE, OR EXHAUSE SMOKE IS BLUE......................................................................323
			S-9  OIL BECOMES CONTAMINATED QUICKLY............................................................................................323
			S-10  FUEL CONSUMPTION IS EXCESSIVE..............................................................................................323
			S-11  OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN......................................................323
			S-12  OIL PRESSURE CAUTION LAMP LIGHTS UP, DROP IN OIL PRESSURE..................................................................323
			S-13  OIL LEVEL RISES COOLANT, FUIL IN OIL.......................................................................................324
			S-14  COOLANT TEMPERATURE BECOMES TOO HIGH: OVERHEATING..........................................................................325
			S-15  ABNORMAL NOISE IS MADE.....................................................................................................326
			S-16  VIBRATION IS EXCESSIVE.....................................................................................................327
		TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)......................................................................................329
			TROUBLE DATA DISPLAY.............................................................................................................331
			M-1  MAIN MONITOR DOES NOT WORK..................................................................................................333
			M-2  WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED IMMEDIATELY, ALL LAMPS STAY LIT.....................................334
			M-3  SPEEDOMETER DISPLAY DOES NOT WORK PROPERLY..................................................................................335
			M-4  ABNORMALITY IN SHIFT INDICATOR..............................................................................................336
			M-5  HIGH BEAM DOES NOT LIGHT UP.................................................................................................339
			M-6  TURN SIGNAL DISPLAY DOES NOT LIGHT UP.......................................................................................340
			M-7  ABNORMALITY IN PARKING DISPLAY..............................................................................................341
			M-8             N/A..............................................................................................................342
			M-9  TAIL LIGHTS DO NOT ILLUMNATE................................................................................................343
			M-10  ABNORMALITY IN FRONT WORKING LAMP..........................................................................................344
			M-11  ABNORMALITY IN REAR WORKING LAMP...........................................................................................345
			M-12  ABNORMALITY IN TRANSMISSION CUT-OFF........................................................................................347
			M-13  ABNORMALITY IN PARKING BRAKE APPLIED WARNING...............................................................................349
			M-14  WHEN PARKING BRAKE IS APPLIED, BUZZER AND CAUTION LAMP ARE ALWAYS ON OR ALWAYS OFF.........................................350
			M-15  ABNORMALITY IN BUZZER......................................................................................................351
			M-16  CONDITION OF MONITOR SWITCHES IS NOT STORED IN MEMORY......................................................................352
			M-17  ABNORMALITY IN FAILURE DISPLAY MODE........................................................................................353
			M-18  ABNORMALITY IN GROUND DRIVEN STEERING NORMAL DISPLAY.......................................................................354
			M-19  ABNORMALITY IN GROUND DRIVEN STEERING ACTUATION DISPLAY....................................................................355
			M-20             N/A.............................................................................................................356
			M-21  ABNORMALITY IN ECSS SYSTEM.................................................................................................357
			M-22  BUZZER DOES NOT SOUND WHEN AUTO-LEVELING SWITCH IS ACTUATED................................................................357
			M-23  FAILURE CODE IS NOT SENT TO MAIN MONITOR (ABNORMALITY IN NETWORK)..........................................................358
		TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K) MODE...............................................................................359
			K-1  WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT LIGHT UP FOR 3 SECONDS, MAINTENANCE MONITOR D....360
			K-2  WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR ILLUMINATE, BUT DO NOT GO OUT...........................361
			K-3  WHEN ENGINE IS STARTED IMMEDIATELY AFTER STARTING SWITCH IS TURNED ON, ALL LAMPS ON MAINTENANCE MONITOR DO NOT GO OUT.......362
			K-4  WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH.......................................................363
			K-5  WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH.....................................................365
			K-6  CAUTION ITEMS ARE FLASHING, BUT ALARM BUZZER DOES NOT SOUND.................................................................369
			K-7  THERE IS NOT ABNORMALITY IN MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS........................................................370
			K-8  CAUTION ITEMS ARE FLASHING, BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) DOES NOT ILLUMINATE.................................371
			K-9  THERE IS NOT ABNORMALITY IN MAINTENANCE MONITOR DISPLAY, BUT WARNING LAMP (CHECK LAMP, CAUTION LAMP) ILLUMINATES............372
			K-10  NIGHT LIGHTING DOES NOT ILLUMINATE WHEN LAMP SWITCH IS TURNED ON (ONLY LIGHTING OF MAINTENANCE MONITOR DOES NOT ILLUMIN....373
			K-11  NIGHT LIGHTING ILLUMINATES EVEN WHEN LAMP SWITCH IS OFF, NIGHT LIGHTING STAYS ILLUMINATED..................................374
			K-12  SERVICE METER DOES NOT WORK................................................................................................375
			K-13  SERVICE METER IS RUNNING EVEN WHEN ENGINE IS STOPPED.......................................................................375
			K-14  ABNORMALITY IN GAUGE ITEMS.................................................................................................376
		TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)........................................................................................379
			E-1  ENGINE DOES NOT START.......................................................................................................381
			E-2  ENGINE DOES NOT STOP........................................................................................................384
			E-3  ENGINE STOPS WHEN MACHINE IS TRAVELING......................................................................................384
			E-4  PARKING BRAKE DOES NOT WORK.................................................................................................385
			E-5  PARKING BRAKE IS APPLIED WHEN MACHINE IS TRAVELING..........................................................................386
			E-6  PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON.................................................................387
		TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (CHASSIS RELATED) (T MODE)........................................................388
			POWER TRAIN......................................................................................................................390
				T-1  MACHINE DOES NOT MOVE...................................................................................................390
				T-2  TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES....................................................391
				T-3  EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEARS.................................................................392
				T-4  EXCESSIVE TIME LAG WHEN STARTING TO MOVE MACHINE OR AFTER SHIFTING GEARS................................................393
				T-5  TORQUE CONVERTER OIL TEMPERATURE IS HIGH................................................................................394
			STEERING SYSTEM..................................................................................................................395
				T-6  STEERING WHEEL DOES NOT TURN............................................................................................395
				T-7  STEERING IS HEAVY.......................................................................................................396
				T-8  STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK.......................................................................397
				T-9             N/A..........................................................................................................398
				T-10           N/A...........................................................................................................398
			BRAKE SYSTEM.....................................................................................................................399
				T-11  BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR...........................................................................399
				T-12  BRAKES ARE NOT RELEASED OR BRAKES DRAG.................................................................................400
				T-13  PARKING BRAKE IS NOT RELEASED OR BRAKES DRAG...........................................................................401
			WORK EQUIPMENT...................................................................................................................402
				T-14  BOOM DOES NOT RISE.....................................................................................................402
				T-15  BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER......................................................................403
				T-16  WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT...............................................................404
				T-17  BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS).............................................................404
				T-18  EXCESSIVE HYDRAULIC DRIFT OF BOOM......................................................................................404
				T-19  BOOM SHAKES DURING OPERATION...........................................................................................404
				T-20  BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE...............................................405
				T-21  BUCKET DOES NOT TILT BACK..............................................................................................406
				T-22  BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER.......................................................................407
				T-23  BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION................................................................408
				T-24  BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER...........................................................................408
				T-25  EXCESSIVE HYDRAULIC DRIFT OF BUCKET....................................................................................408
				T-26  BUCKET SHAKES DURING LOADING OPERATION (MAIN CONTROL VALVE AT HOLD)....................................................409
				T-27  BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT..............................................409
				T-28  BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY..........................................................410
		TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE).......................................................411
			JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM.................................................................................412
			D-1  ECSS DOES NOT WORK..........................................................................................................413
			D-2  ECSS CANNOT BE CANCELED.....................................................................................................420
			D-3  OUTPUT IS TURNED ON (TRAVEL SPEED DOES NOT BECOME 5KM/H)  (DEVIATES AROUND 5 KM/H)..........................................421
			D-4  OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 1ST.............................................................................421
			D-5  OUTPUT IS TURNED ON WHEN TRANSMISSION IS IN 4TH.............................................................................422
			D-6  CONTROLLER LED CODE IS NOT DISPLAYED........................................................................................423
			D-7  ECSS  IS ABNORMAL, BUT MAIN MONITOR DOES NOT GIVE ABNORMALITY...............................................................423
		TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (WITH AUTO-SHIFT TRANSMISSION) (A MODE)............................................424
			OUTLINE..........................................................................................................................425
			ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM....................................................................429
			A-1  TROUBLESHOOTING CODE [12]F SOLENOID SIGNAL SYSTEM...........................................................................431
			A-2  TROUBLESHOOTING CODE [13]R SOLENOID SIGNAL SYSTEM...........................................................................431
			A-3  TROUBLESHOOTING CODE [14]  ABNORMALITY IN H-L  SOLENOID SIGNAL SYSTEM.......................................................432
			A-4  TROUBLESHOOTING CODE [16]  ABNORMALITY IN SPEED SOLENOID SIGNAL SYSTEM......................................................433
			A-5  TROUBLESHOOTING CODE[20]  ABNORMALITY IN DIRECTIONAL LEVER SIGNAL SYSTEM....................................................434
			A-6  TROUBLESHOOTING CODE [21]  ABNORMALITY IN SPEED LEVER SIGNAL SYSTEM.........................................................435
			A-7  TROUBLESHOOTING CODE [22]  ABNORMALITY IN TRAVEL SPEED SIGNAL SYSTEM........................................................436
			A-8  TROUBLESHOOTING CODE [23] ABNORMALITY IN ENGINE SPEED SIGNAL................................................................437
			A-9  HOLD SWITCH SYSTEM..........................................................................................................438
			A-10  KICK-DOWN SWITCH SYSTEM....................................................................................................438
			A-11  TRANSMISSION CUT-OFF SIGNAL SYSTEM.........................................................................................439
			A-12  NEUTRALIZER RELAY SIGNAL SYSTEM............................................................................................440
			A-13  BUZZER SIGNAL SYSTEM.......................................................................................................441
			A-14  NETWORK SIGNAL SYSTEM......................................................................................................442
			A-15  CONTROLLER POWER SOURCE SYSTEM.............................................................................................443
30 DISASSEMBLY AND ASSEMBLY..................................................................................................................444
	METHOD OF USING MANUAL...................................................................................................................446
	PRECAUTIONS WHEN CARRYING OUT OPERATION..................................................................................................447
		1. PRECAUTIONS WHEN CARRYING OUT REMOVAL WORK........................................................................................447
		2. PRECAUTIONS WHEN CARRYING OUT INSTALLATION WORK...................................................................................448
		3. PRECAUTIONS WHEN COMPLETING THE OPERATIONS........................................................................................449
	SPECIAL TOOL LIST........................................................................................................................450
	SKETCHES OF SPECIAL TOOLS................................................................................................................452
	STARTER MOTOR............................................................................................................................453
	REMOVAL..................................................................................................................................453
	INSTALLATION.............................................................................................................................453
	ALTERNATOR...............................................................................................................................454
	REMOVAL..................................................................................................................................454
	INSTALLATION.............................................................................................................................454
	REMOVAL OF RADIATOR ASSEMBLY.............................................................................................................455
	INSTALLATION OF RADIATOR ASSEMBLY........................................................................................................460
	REMOVAL OF ENGINE ASSEMBLY...............................................................................................................461
	INSTALLATION OF ENGINE ASSEMBLY..........................................................................................................465
	REMOVAL OF TORQUE CONVERTER CHARGING PUMP ASSEMBLY.......................................................................................466
	INSTALLATION OF TORQUE CONVERTER CHARGING PUMP ASSEMBLY..................................................................................466
	REMOVAL OF TORQUE CONVERTER TRANSMISSION ASSEMBLY........................................................................................467
	INSTALLATION OF TORQUE CONVERTER, TRANSMISSION ASSEMBLY..................................................................................480
	DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY.................................................................................................483
	ASSEMBLY OF TORQUE CONVERTER ASSEMBLY....................................................................................................485
	DISASSEMBLY OF TRANSMISSION ASSEMBLY.....................................................................................................487
	ASSEMBLY OF TRANSMISSION ASSEMBLY........................................................................................................497
	DISASSEMBLY OF TRANSMISSION CLUTCH PACK ASSEMBLY.........................................................................................511
	DISASSEMBLY OF 1ST, 3RD CLUTCH...........................................................................................................513
	ASSEMBLY OF TRANSMISSION CLUTCH PACK ASSEMBLY............................................................................................517
	ASSEMBLY OF FORWARD, REVERSE CLUTCH PACK.................................................................................................517
	ASSEMBLY OF 1ST, 3RD CLUTCH PACK.........................................................................................................521
	REMOVAL OF TRANSMISSION CONTROL VALVE ASSEMBLY...........................................................................................529
	INSTALLATION OF TRANSMISSION CONTROL VALVE ASSEMBLY......................................................................................531
	DISASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY.......................................................................................532
	ASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY..........................................................................................534
	DISASSEMBLY OF TRANSMISSION ACCUMULATOR VALVE ASSEMBLY...................................................................................537
	ASSEMBLY OF TRANSMISSION ACCUMULATOR VALVE ASSEMBLY......................................................................................538
	DISASSEMBLY OF TRANSMISSION MODULATING VALVE ASSEMBLY....................................................................................539
	ASSEMBLY OF TRANSMISSION MODULATING VALVE ASSEMBLY.......................................................................................540
	DISASSEMBLY OF DRIVE SHAFT ASSEMBLY......................................................................................................541
	ASSEMBLY OF DRIVE SHAFT ASSEMBLY.........................................................................................................543
	REMOVAL OF FRONT AXLE....................................................................................................................545
	INSTALLATION OF FRONT AXLE ASSEMBLY......................................................................................................547
	REMOVAL OF REAR AXLE ASSEMBLY............................................................................................................548
	INSTALLATION OF REAR AXLE ASSEMBLY.......................................................................................................552
	DISASSEMBLY OF DIFFERENTIAL ASSEMBLY.....................................................................................................553
	ASSEMBLY OF DIFFERENTIAL ASSEMBLY........................................................................................................557
	DISASSEMBLY OF AXLE HOUSING ASSEMBLY.....................................................................................................566
	ASSEMBLY OF AXLE HOUSING ASSEMBLY........................................................................................................572
	REMOVAL OF CENTER HINGE PIN..............................................................................................................580
	INSTALLATION OF CENTER HINGE PIN.........................................................................................................585
	REMOVAL OF PRIORITY VALVE................................................................................................................589
	INSTALLATION OF PRIORITY VALVE ASSEMBLY..................................................................................................590
	REMOVAL OF STEERING VALVE ASSEMBLY.......................................................................................................591
	INSTALLATION OF STEERING VALVE ASSEMBLY..................................................................................................592
	DISASSEMBLY OF STEERING VALVE............................................................................................................593
	DISASSEMBLY OF CONTROL SIDE..............................................................................................................594
	ASSEMBLY OF STEERING VALVE...............................................................................................................596
	ASSEMBLY OF CONTROL SIDE.................................................................................................................596
	ASSEMBLY OF ROTOR........................................................................................................................598
	REMOVAL OF STEERING CYLINDER ASSEMBLY....................................................................................................601
	INSTALLATION OF STEERING CYLINDER ASSEMBLY...............................................................................................602
	DISASSEMBLY OF RIGHT BRAKE VALVE ASSEMBLY (TANDEM).......................................................................................603
	ASSEMBLY OF RIGHT BRAKE VALVE ASSEMBLY (TANDEM)..........................................................................................604
	DISASSEMBLY OF LEFT BRAKE VALVE ASSEMBLY (SINGLE)........................................................................................605
	ASSEMBLY OF LEFT BRAKE VALVE ASSEMBLY (SINGLE)...........................................................................................606
	REMOVAL OF PARKING BRAKE DISC............................................................................................................607
	INSTALLATION OF PARKING BRAKE DISC.......................................................................................................609
	REMOVAL OF HYDRAULIC TANK ASSEMBLY.......................................................................................................610
	INSTALLATION OF HYDRAULIC TANK ASSEMBLY..................................................................................................611
	REMOVAL OF HYDRAULIC FILTER ASSEMBLY.....................................................................................................612
	INSTALLATION OF HYDRAULIC FILTER ASSEMBLY................................................................................................612
	REMOVAL OF HYDRAULIC STEERING PUMP ASSEMBLY..............................................................................................613
	INSTALLATION OF HYDRAULIC STEERING PUMP ASSEMBLY.........................................................................................619
	REMOVAL OF MAIN CONTROL VALVE ASSEMBLY...................................................................................................620
	INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY..............................................................................................621
	DISASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY...............................................................................................622
	ASSEMBLY OF MAIN CONTROL VALVE ASSEMBLY..................................................................................................624
	DISASSEMBLY OF 3-SPOOL CONTROL VALVE ASSEMBLY............................................................................................627
	ASSEMBLY OF 3-SPOOL CONTROL VALVE ASSEMBLY...............................................................................................629
	REMOVAL OF PPC VALVE ASSEMBLY............................................................................................................632
	INSTALLATION OF PPC VALVE ASSEMBLY.......................................................................................................633
	DISASSEMBLY OF PPC VALVE ASSEMBLY........................................................................................................634
	ASSEMBLY OF PPC VALVE ASSEMBLY...........................................................................................................635
	REMOVAL OF BUCKET CYLINDER ASSEMBLY......................................................................................................636
	INSTALLATION OF BUCKET CYLINDER..........................................................................................................637
	REMOVAL OF BOOM CYLINDER.................................................................................................................638
	INSTALLATION OF BOOM CYLINDER ASSEMBLY...................................................................................................639
	DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY...............................................................................................640
	STEERING, BOOM, BUCKET CYLINDER ASSEMBLY.................................................................................................640
	ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY..................................................................................................643
	REMOVAL OF WORK EQUIPMENT ASSEMBLY.......................................................................................................646
	INSTALLATION OF WORK EQUIPMENT ASSEMBLY..................................................................................................649
	REMOVAL OF COUNTERWEIGHT.................................................................................................................651
	INSTALLATION OF COUNTERWEIGHT............................................................................................................651
	REMOVAL OF FUEL TANK ASSEMBLY............................................................................................................652
	INSTALLATION OF FUEL TANK ASSEMBLY.......................................................................................................654
	REMOVAL OF CAB ASSEMBLY..................................................................................................................655
	INSTALLATION OF CAB ASSEMBLY.............................................................................................................656
	REMOVAL OF MAIN MONITOR ASSEMBLY.........................................................................................................657
	INSTALLATION OF MAIN MONITOR ASSEMBLY....................................................................................................658
	REMOVAL OF MAINTENANCE MONITOR ASSEMBLY..................................................................................................659
	INSTALLATION OF MAINTENANCE MONITOR ASSEMBLY.............................................................................................659
	REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY.................................................................................................660
	INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY............................................................................................665
	REMOVAL OF AIR CONDITIONER CONDENSER ASSEMBLY............................................................................................666
	INSTALLATION OF AIR CONDITIONER CONDENSER ASSEMBLY.......................................................................................667
	REMOVAL OF DRYER RECEIVER ASSEMBLY.......................................................................................................668
	INSTALLATION OF DRYER RECEIVER ASSEMBLY..................................................................................................668
	REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY...........................................................................................669
	INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY......................................................................................670
40 MAINTENANCE STANDARD......................................................................................................................672
	ENGINE MOUNT, TRANSMISSION MOUNT.........................................................................................................673
	TORQUE CONVERTER CHARGING PUMP...........................................................................................................674
	TORQUE CONVERTER.........................................................................................................................675
	TRANSMISSION.............................................................................................................................676
	FORWARD/REVERSE CLUTCH...................................................................................................................681
	1ST AND 3RD CLUTCH.......................................................................................................................683
	2ND AND 4TH CLUTCH.......................................................................................................................684
	TRANSMISSION CONTROL VALVE...............................................................................................................685
	MODULATION VALVE ASSEMBLY................................................................................................................689
	ACCUMULATOR VALVE........................................................................................................................690
	DIFFERENTIAL.............................................................................................................................692
	LIMITED SLIP DIFFERENTIAL (OPTIONAL).....................................................................................................695
	FINAL DRIVE..............................................................................................................................696
	AXLE MOUNT...............................................................................................................................698
	CENTER HINGE PIN.........................................................................................................................700
	STEERING COLUMN..........................................................................................................................702
	PRIORITY VALVE...........................................................................................................................703
	STEERING CYLINDER MOUNT..................................................................................................................704
	BRAKE....................................................................................................................................705
	BRAKE VALVE..............................................................................................................................706
	PARKING BRAKE............................................................................................................................709
	HYDRAULIC PUMP (HYDRAULIC, STEERING, SWITCH, PPC PUMP)...................................................................................710
	MAIN CONTROL VALVE.......................................................................................................................711
		2-SPOOL VALVE........................................................................................................................711
		3-SPOOL VALVE (OPTIONAL).............................................................................................................713
	PPC VALVE................................................................................................................................715
	HYDRAULIC CYLINDER.......................................................................................................................716
	WORK EQUIPMENT LINKAGE...................................................................................................................717
	BUCKET...................................................................................................................................719
	BUCKET POSITIONER AND BOOM KICK-OUT......................................................................................................720
90 OTHERS....................................................................................................................................722
	ELECTRICAL CIRCUIT DIAGRAM (1 OF4) WA320-3MC/WA380-3MC...................................................................................723
	ELECTRICAL CIRCUIT DIAGRAM (2 OF 4) WA320-3MC/WA380-3MC..................................................................................724
	ELECTRICAL CIRCUIT DIAGRAM (3 OF 4) WA320-3MC............................................................................................725
	ELECTRICAL CIRCUIT DIAGRAM (4 OF 4) WA320-3MC............................................................................................726

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