Komatsu WA320-3MC Wheel Loader Shop Manual CEBM003302 – PDF DOWNLOAD

Description

Komatsu WA320-3MC Wheel Loader Shop Manual CEBM003302 – PDF DOWNLOAD

FILE DETAILS:

Komatsu WA320-3MC Wheel Loader Shop Manual CEBM003302 – PDF DOWNLOAD

Language : English
Pages : 727
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu WA320-3MC Wheel Loader Shop Manual CEBM003302 – PDF DOWNLOAD

• MACHINE MODEL                            SERIAL NUMBERS
• WA320-3MC                                      A31001 and up

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

DESCRIPTION:

Komatsu WA320-3MC Wheel Loader Shop Manual CEBM003302 – PDF DOWNLOAD

• MACHINE MODEL                            SERIAL NUMBERS
• WA320-3MC                                      A31001 and up

GENERAL;
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate
understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure
you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop.
For ease of understanding, the manual is divided into the following 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.

G.B  16/12/24