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KOMATSU WA320-5 SHOP MANUAL SEBM0346-09 – PDF DOWNLOAD
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Description
KOMATSU WA320-5 SHOP MANUAL SEBM0346-09 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA320-5 SHOP MANUAL SEBM0346-09 – PDF DOWNLOAD
Language : English
Pages : 854
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA320-5 SHOP MANUAL SEBM0346-09 – PDF DOWNLOAD
COVER .................................................................................................................................................................................. 1 CONTENTS ............................................................................................................................................................................... 2 LIST OF REVISED PAGES................................................................................................................................................................... 3 01 GENERAL ............................................................................................................................................................................. 27 GENERAL ASSEMBLY DRAWINGS........................................................................................................................................................... 28 SPECIFICATIONS...................................................................................................................................................................... 29 WEIGHT TABLE........................................................................................................................................................................ 33 LIST OF LUBRICANT AND COOLANT....................................................................................................................................................... 35 10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD.......................................................................................................................................... 37 ENGINE MOUNT AND TRANSFER MOUNT..................................................................................................................................................... 38 DAMPER.............................................................................................................................................................................. 39 COOLING SYSTEM...................................................................................................................................................................... 40 POWER TRAIN......................................................................................................................................................................... 43 POWER TRAIN SYSTEM DIAGRAM.......................................................................................................................................................... 44 DRIVE SHAFT (PROPELLER SHAFT)....................................................................................................................................................... 46 HST HYDRAULIC PIPING DIAGRAM........................................................................................................................................................ 47 HST PUMP............................................................................................................................................................................ 48 HIGH-PRESSURE RELIEF VALVE.......................................................................................................................................................... 50 LOW-PRESSURE RELIEF VALVE........................................................................................................................................................... 52 HST CHARGE PUMP..................................................................................................................................................................... 53 SPEED-RELATED VALVE (DA VALVE)...................................................................................................................................................... 54 HIGH-PRESSURE CUT-OFF VALVE......................................................................................................................................................... 55 HST MOTOR........................................................................................................................................................................... 56 EP SERVO VALVE...................................................................................................................................................................... 59 HA SERVO VALVE...................................................................................................................................................................... 60 FORWARD-REVERSE SHUTTLE VALVE....................................................................................................................................................... 61 TRANSFER............................................................................................................................................................................ 62 CLUTCH SOLENOID VALVE............................................................................................................................................................... 73 AXLE................................................................................................................................................................................ 74 DIFFERENTIAL........................................................................................................................................................................ 76 LIMITED-SLIP DIFFERENTIAL........................................................................................................................................................... 84 FINAL DRIVE......................................................................................................................................................................... 88 AXLE MOUNTING AND CENTER HINGE PIN.................................................................................................................................................. 90 STEERING PIPING..................................................................................................................................................................... 95 STEERING COLUMN..................................................................................................................................................................... 96 PRIORITY VALVE...................................................................................................................................................................... 97 ORBIT-ROLL VALVE....................................................................................................................................................................100 CUSHION VALVE.......................................................................................................................................................................108 STEERING CYLINDER...................................................................................................................................................................109 EMERGENCY STEERING PIPING...........................................................................................................................................................111 EMERGENCY STEERING VALVE............................................................................................................................................................112 BRAKE PIPING........................................................................................................................................................................115 BRAKE VALVE.........................................................................................................................................................................116 INCHING VALVE.......................................................................................................................................................................120 CHARGE VALVE........................................................................................................................................................................122 ACCUMULATOR (FOR BRAKE).............................................................................................................................................................126 SLACK ADJUSTER......................................................................................................................................................................128 BRAKE...............................................................................................................................................................................130 PARKING BRAKE CONTROL...............................................................................................................................................................132 PARKING BRAKE.......................................................................................................................................................................133 HYDRAULIC PIPING....................................................................................................................................................................134 WORK EQUIPMENT LEVEL LINKAGE........................................................................................................................................................136 HYDRAULIC TANK......................................................................................................................................................................138 4-GEAR PUMP UNIT....................................................................................................................................................................140 ACCUMULATOR (FOR PPC CIRCUIT).......................................................................................................................................................142 LOCK VALVE..........................................................................................................................................................................143 E.C.S.S. VALVE......................................................................................................................................................................144 ACCUMULATOR (FOR E.C.S.S.)..........................................................................................................................................................146 HYDRAULIC PIPING OF COOLING SYSTEM..................................................................................................................................................147 COOLING FAN MOTOR...................................................................................................................................................................148 WORK EQUIPMENT CONTROL VALVE........................................................................................................................................................151 WORK EQUIPMENT PPC VALVE............................................................................................................................................................172 ATTACHMENT PPC VALVE................................................................................................................................................................184 WORK EQUIPMENT LINKAGE..............................................................................................................................................................188 BUCKET..............................................................................................................................................................................190 BUCKET POSITIONER AND BOOM KICK-OUT.................................................................................................................................................192 WORK EQUIPMENT CYLINDER.............................................................................................................................................................198 AIR CONDITIONER.....................................................................................................................................................................199 MACHINE MONITORING SYSTEM...........................................................................................................................................................200 MACHINE MONITOR.....................................................................................................................................................................210 LIST OF ITEMS DISPLAYED ON MONITOR..................................................................................................................................................211 ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)...........................................................................................................................................237 HST CONTROLLER......................................................................................................................................................................241 KOMTRAX SYSTEM......................................................................................................................................................................242 ENGINE START CIRCUIT................................................................................................................................................................244 ENGINE STOP CIRCUIT.................................................................................................................................................................246 PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)....................................................................................................................................247 PARKING BRAKE CIRCUIT...............................................................................................................................................................248 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM.........................................................................................................................................251 SENSORS.............................................................................................................................................................................252 20 TESTING AND ADJUSTING................................................................................................................................................................261 STANDARD VALUE TABLE FOR ENGINE.....................................................................................................................................................262 STANDARD VALUE TABLE FOR CHASSIS....................................................................................................................................................263 TESTING AND ADJUSTING...............................................................................................................................................................267 TOOLS FOR TESTING, ADJUSTING,AND TROUBLESHOOTING................................................................................................................................268 MEASURING ENGINE SPEED..........................................................................................................................................................270 MEASURING EXHAUST GAS COLOR.....................................................................................................................................................271 ADJUSTING VALVE CLEARANCE.......................................................................................................................................................273 MEASURING COMPRESSION PRESSURE..................................................................................................................................................274 MEASURING BLOW-BY PRESSURE......................................................................................................................................................275 TESTING AND ADJUSTING FUEL INJECTION TIMING.....................................................................................................................................276 MEASURING ENGINE OIL PRESSURE...................................................................................................................................................277 MEASURING, TESTING OPERATION FORCE OF ACCELERATOR PEDAL.........................................................................................................................278 ADJUSTING ENGINE STOP SOLENOID..................................................................................................................................................280 ADJUSTING ENGINE SPEED SENSOR...................................................................................................................................................281 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...................................................................................................................281 MEASURING DIRECTIONAL LEVER.....................................................................................................................................................282 TESTING AND ADJUSTING HST OIL PRESSURE..........................................................................................................................................282 MEASURING CLUTCH CONTROL PRESSURE...............................................................................................................................................287 TESTING AND ADJUSTING STEERING WHEEL............................................................................................................................................288 TESTING AND ADJUSTING STEERING OIL PRESSURE.....................................................................................................................................289 BLEEDING AIR FROM STEERING CIRCUIT..............................................................................................................................................290 TESTING HYDRAULIC FAN...........................................................................................................................................................291 MEASURING BRAKE PEDAL...........................................................................................................................................................292 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE.......................................................................................................................................293 MEASURING BRAKE PERFORMANCE.....................................................................................................................................................294 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE...............................................................................................................................295 MEASURING BRAKE OIL PRESSURE....................................................................................................................................................296 MEASURING WEAR OF BRAKE DISC....................................................................................................................................................298 BLEEDING AIR FROM BRAKE CIRCUIT.................................................................................................................................................299 MEASURING PARKING BRAKE PERFORMANCE.............................................................................................................................................300 TESTING AND ADJUSTING PARKING BRAKE LINKAGE.....................................................................................................................................301 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER............................................................................................................................302 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE.........................................................................................................................303 TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE...........................................................................................................................304 BLEEDING AIR....................................................................................................................................................................306 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...............................................................................................................................307 TESTING AND ADJUSTING BUCKET POSITIONER.........................................................................................................................................307 TESTING AND ADJUSTING OF BOOM KICK-OUT..........................................................................................................................................309 CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP................................................................................................................................310 PROCEDURE FOR CHECKING DIODE....................................................................................................................................................311 METHOD OF CONNECTING T-ADAPTER FOR HST CONTROLLER...............................................................................................................................312 STARTING KOMTRAX TERMINAL OPERATIONS............................................................................................................................................313 INDICATOR LAMPS OF KOMTRAX TERMINAL.............................................................................................................................................317 SPECIAL FUNCTIONS OF MACHINE MONITOR............................................................................................................................................321 FLOW OF MODES AND FUNCTIONS.....................................................................................................................................................322 FAILURE CODE TABLE..............................................................................................................................................................330 PM CLINIC INSPECTION CHART......................................................................................................................................................340 TROUBLESHOOTING.....................................................................................................................................................................343 POINTS TO REMEMBER WHEN TROUBLESHOOTING.........................................................................................................................................344 SEQUENCE OF EVENTS IN TROUBLESHOOTING...........................................................................................................................................345 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.......................................................................................................................................346 CHECKS BEFORE TROUBLESHOOTING...................................................................................................................................................354 CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................................355 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO......................................................................................................................356 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS......................................................................................................................................359 T-ADAPTER TABLE.................................................................................................................................................................382 CONNECTOR TYPES AND MOUNTING LOCATIONS..........................................................................................................................................385 CONNECTOR LAYOUT DRAWING........................................................................................................................................................392 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE).............................................................................................................................397 BEFORE TROUBLESHOOTING CODE DISPLAY.........................................................................................................................................398 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM....................................................................................................................................400 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................................................................401 FAILURE CODE [989F00] (HST MOTOR PROTECTION CAUTION(00))....................................................................................................................403 FAILURE CODE [DHH1KX] (HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE RANGE(KX))..............................................................................................404 FAILURE CODE [DLE2LC] (ENGINE REVOLUTION SENSOR REVOLUTION SPEED SIGNAL MISMATCH (LC))......................................................................................406 FAILURE CODE [DW26KZ] (MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING(KZ)).......................................................................................408 FAILURE CODE [DX19KZ] (MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))......................................................................................410 FAILURE CODE [DX20KZ] (CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)).......................................................................................412 TROUBLESHOOTING CODE [HST-1](DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))......................................................................414 TROUBLESHOOTING CODE [HST-2] (TRAVEL SPEED DOES NOT SHIFTED)................................................................................................................416 TROUBLESHOOTING CODE [HST-3] HST OUTPUT CONTROL(TRACTION CONTROL) CANNOT BE CONTROLLED......................................................................................420 TROUBLESHOOTING CODE [HSR-4] (TRAVEL SPEED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN "1ST" POSITION)....................................................422 TROUBLESHOOTING CODE [HST-5] (TRAVEL SPEED IS NOT INCREASED)................................................................................................................424 TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM(ECSS MODE)..............................................................................................................................425 RELATED ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................................................426 ECSS-1 MALFUNCTION OF TRAVEL DAMPER.........................................................................................................................................427 TROUBLESHOOTING OF MONITOR SYSTEM(MON MODE).....................................................................................................................................433 BEFORE TROUBLESHOOTING CODE DISPLAY.........................................................................................................................................436 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM....................................................................................................................................438 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................................................................439 FAILURE CODE [15B0NX] (HST OIL FILTER CLOGGED (NX))........................................................................................................................441 FAILURE CODE [2G42ZG] (DECREASED BRAKE OIL PRESSURE(ZG))...................................................................................................................442 FAILURE CODE [989FOO] (HST MOTOR PROTECTION CAUTION (OO))...................................................................................................................443 FAILURE CODE [989FN1] (HST OVERRUNNING (N1))................................................................................................................................444 FAILURE CODE [AA1ANX] (CLOGGING OF AIR CLEANER (NX))........................................................................................................................446 FAILURE CODE [ABOOL6] (DEFECTIVE BATTERY CHARGING CIRCUIT(L6))..............................................................................................................448 FAILURE CODE [ABOOMA] (DEFECTIVE BATTERY CHARGING CIRCUIT (MA)).............................................................................................................449 FAILURE CODE [B@BAZG] (DEGREASED ENGINE OIL PRESSURE(ZG))...................................................................................................................450 FAILURE CODE [B@BAZK] LOWERING OF ENGINE OIL LEVEL(ZK)......................................................................................................................451 FAILURE CODE [B@BCNS] (ENGINE WATER TEMPERATURE OVERHEATING(NS))............................................................................................................452 FAILURE CODE [B@BCZK] (ALARM INDICATING LOW COOLANT LEVEL(ZK))..............................................................................................................453 FAILURE CODE [B@C7NS] (AXLE OIL TEMPERATURE OVERHEATING(NS))................................................................................................................454 FAILURE CODE [B@CRNS] (HST OIL TEMPERATURE OVERHEATING(NS)).................................................................................................................455 FAILURE CODE [D5ZHL6] (STARTING SWITCH "C"(IGN"C")INPUT FAILURE(L6))........................................................................................................456 FAILURE CODE [DAFOKT] (CONTROLLER INSIDE FAILURE(KT)).......................................................................................................................458 FAILURE CODE [DAJOKR] (HST CONTROLLER COMMUNICATION FAILURE(KR))............................................................................................................460 FAILURE CODE [DD15LD] (MONITOR PANEL MODE SELECTOR SWITCH 1[■](PANEL SWITCH 1)INPUT ERROR(LD))..............................................................................462 FAILURE CODE [DD16LD] (MONITOR PANEL MODE SELECTOR SWITCH 1[◇](PANEL SWITCH 2)INPUT ERROR (LD)..............................................................................463 FAILURE CODE [DD17LD] (MONITOR PANEL MODE SELECTOR SWITCH 2[<](PANEL SWITCH 3)INPUT ERROR (LD)..............................................................................464 FAILURE CODE [DD18LD] (MONITOR PANEL MODE SELECTOR SWITCH 2[>](PANEL SWITCH 4)INPUT ERROR (LD)..............................................................................465 FAILURE CODE [DDK3KB] (MULTIPLE DIRECTIONAL LEVER FR SIGNAL INPUT (KB)).....................................................................................................466 FAILURE CODE [DDS5L6] (DECREASED STEERING OIL PRESSURE(L6)).................................................................................................................468 FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE (HIGH TEMPERATURE) SENSOR SYSTEM FAILURE(KX))...............................................................................469 FAILURE CODE [DGE3L6] (ENGINE WATER TEMPERATURE (LOW TEMPERATURE)SENSOR SYSTEM FAILURE(L6)).................................................................................470 FAILURE CODE [DGH1LX] (HST OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX)).......................................................................................................471 FAILURE CODE [DGR4KA] (AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY(KA))................................................................................................472 FAILURE CODE [DGR4KX] (AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))......................................................................................................473 FAILURE CODE [DHE4L6] (ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY(L6)).................................................................................................474 TROUBLESHOOTING CODE [MON-1] (THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)...........................................................................................476 TROUBLESHOOTING CODE [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)........................................................................................480 TROUBLESHOOTING CODE [MON-3] (THE ENGINE WATER TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE ENGINE WATER TEMPERATURE GAUGE DOES NOT RISE.) ....481 TROUBLESHOOTING CODE [MON-4] (THE HST OIL TEMPERATURE CAUTION LAMP DOES NOT LIGHT ON,OR AFTER THE ENGINE STARTS,THE HST OIL TEMPERATURE GAUGE DOES NOT RISE.) ..............482 TROUBLESHOOTING CODE [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.)..............................................................................................483 TROUBLESHOOTING CODE [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON)....................................................................................484 TROUBLESHOOTING CODE [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON).....................................................................................485 TROUBLESHOOTING CODE [MON-6] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON).........................................................................486 TROUBLESHOOTING CODE [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1[■](PANEL SWITCH 1)).....................................................................487 TROUBLESHOOTING CODE [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1[◇](PANEL SWITCH 2))....................................................................488 TROUBLESHOOTING CODE [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2[<](PANEL SWITCH 3))....................................................................489 TROUBLESHOOTING CODE [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2[>](PANEL SWITCH 4))....................................................................490 TROUBLESHOOTING CODE [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP).....................................................................................................492 TROUBLESHOOTING CODE [MON-14] ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT UP...............................................................................................494 TROUBLESHOOTING CODE [MON-15] (AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP).......................................................................................496 TROUBLESHOOTING CODE [MON-16] THE WIPER DOES NOT FUNCTION...................................................................................................................498 TROUBLESHOOTING CODE [MON-17] (THE LAMPS DO NOT WORK PROPERLY)..............................................................................................................498 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...................................................................................................................................499 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM....................................................................................................................................500 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................................................................501 TROUBLESHOOTING CODE [E-1](THE ENGINE DOES NOT START).......................................................................................................................504 TROUBLESHOOTING CODE [E-2](THE ENGINE DOES NOT STOP)........................................................................................................................510 TROUBLESHOOTING CODE [E-3](PREHEATING IS IMPOSSIBLE OR CONSTANT)............................................................................................................512 TROUBLESHOOTING CODE [E-4](THE PARKING BRAKE (MECHANICAL TYPE) DOES NOT FUNCTION)...........................................................................................516 TROUBLESHOOTING CODE [E-5](DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION)...............................................................................................522 TROUBLESHOOTING CODE [E-6](DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)...........................................................................................526 TROUBLESHOOTING CODE [E-7](DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION)...................................................................................529 TROUBLESHOOTING CODE [E-8](TRAVEL DIRECTION IS NOT CHANGED NORMALLY)........................................................................................................530 TROUBLESHOOTING CODE [E-9](THE WIPER DOES NOT FUNCTION).....................................................................................................................536 TROUBLESHOOTING CODE [E-10](THE WINDOW WASHER DOES NOT FUNCTION)............................................................................................................542 TROUBLESHOOTING CODE [E-11](LAMPS DO NOT WORK PROPERLY).....................................................................................................................546 TROUBLESHOOTING CODE [E-12](THE HORN DOES NOT SOUND)........................................................................................................................558 TROUBLESHOOTING CODE [E-13](DEFECTIVE THE AIR CONDITIONER)..................................................................................................................560 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM(H MODE).........................................................................................................................573 METHOD OF USING TROUBLESHOOTING CHART.......................................................................................................................................574 FAILURE CODE AND CAUSE TABLE................................................................................................................................................576 H-1 THE MACHINE DOES NOT START..............................................................................................................................................578 H-2 THE TRAVEL SPEED IS SLOW................................................................................................................................................579 H-3 THE THRUSTING FORCE IS WEAK.............................................................................................................................................580 H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY..........................................................................................................581 H-5 THE GEAR IS NOT SHIFTED ................................................................................................................................................582 H-6 THE STEERING WHEEL DOES NOT TURN........................................................................................................................................583 H-7 THE STEERING WHEEL IS HEAVY.............................................................................................................................................584 H-8 STEERING WHEEL SHAKES OR JERKS..........................................................................................................................................585 H-10 THE BRAKE DOES NOT WORK OR NOES NOT WORK WELL .........................................................................................................................586 H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED................................................................................................................................587 H-12 THE LIFT ARM DOES NOT RISE OR LOWER....................................................................................................................................588 H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT.................................................................................................589 H-14 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT ......................................................................................................590 H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET(THE BUCKET RISES IN THE AIR).........................................................................................590 H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN...........................................................................................................................590 H-17 THE LIFT ARM WOBBLES DURING OPERATION..................................................................................................................................590 H-18 WHEN THE CONTROL LEVEL IS SWITCHED FROM "HOLD" TO "RAISE", THE LIFT ARM FALLS TEMPORARILY .............................................................................591 H-19 THE BUCKET DOES NOT TILT BACK..........................................................................................................................................592 H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT......................................................................................................593 H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING BACK.........................................................................................................594 H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET........................................................................................................................594 H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN.............................................................................................................................594 H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO "HOLD")................................................................................595 H-25 WHEN THE CONTROL LEVEL IS SWITCHED FROM "HOLD"TO "TILT",THE BUCKET FALLS TEMPORARILY...................................................................................595 H-26 THE CONTROL LEVELS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY...........................................................................................595 H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES.....................................................................................................596 TROUBLESHOOTING OF ENGINE (S MODE)..............................................................................................................................................597 METHOD OF USING TROUBLESHOOTING CHARTS .....................................................................................................................................598 S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)................................................................................................................602 S-2 ENGINE DOES NOT START...................................................................................................................................................604 (1)ENGINE DOES NOT TURN.................................................................................................................................................604 (2)ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED)..............................................................................................605 (3)EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED)............................................................................................606 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR).....................................................................................................................607 S-4 ENGINE STOPS DURING OPERATIONS..........................................................................................................................................608 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)................................................................................................................................609 S-6 ENGINE LACKS OUTPUT(OR LACKS POWER).....................................................................................................................................610 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)...........................................................................................................................611 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).................................................................................................................612 S-9 OIL BECOMES CONTAMINATED QUICKLY........................................................................................................................................613 S-10 FUEL CONSUMPTION IS EXCESSIVE..........................................................................................................................................614 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN..................................................................................................615 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)..............................................................................................................616 S-13 OIL LEVEL RISES(WATER, FUEL IN OIL) ...................................................................................................................................617 S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING) .......................................................................................................................618 S-15 ABNORMAL NOISE IS MADE.................................................................................................................................................619 S-16 VIBRATION IS EXCESSIVE.................................................................................................................................................620 30 DISASSEMBLY AND ASSEMBLY.............................................................................................................................................................621 HOW TO READ THIS MANUAL.............................................................................................................................................................622 PRECAUTIONS WHEN CARRYING OUT OPERATION.............................................................................................................................................624 SPECIAL TOOL LIST...................................................................................................................................................................626 SKETCH OF SPECIAL TOOLS.............................................................................................................................................................629 REMOVAL,INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY................................................................................................................................636 REMOVAL,INSTALLATION OF NOZZLE HOLDER ASSEMBLY......................................................................................................................................640 REMOVAL,INSTALLATION OF CYLINDER HEAD ASSEMBLY......................................................................................................................................642 REMOVAL,INSTALLATION OF ENGINE ASSEMBLY.............................................................................................................................................650 REMOVAL,INSTALLATION OF RADIATOR ASSEMBLY...........................................................................................................................................657 REMOVAL,INSTALLATION OF AIR AFTERCOOLER.............................................................................................................................................658 REMOVAL,INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...............................................................................................................................660 REMOVAL,INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY..........................................................................................................................662 REMOVAL,INSTALLATION OF FUEL TANK ASSEMBLY..........................................................................................................................................664 REMOVAL,INSTALLATION OF TRANSFER....................................................................................................................................................666 DISASSEMBLY,ASSEMBLY OF TRANSFER ASSEMBLY...........................................................................................................................................668 REMOVAL,INSTALLATION OF PARKING BRAKE ASSEMBLY......................................................................................................................................688 DISASSEMBLY,ASSEMBLY OF PARKING BRAKE ASSEMBLY......................................................................................................................................690 REMOVAL,INSTALLATION OF FRONT AXLE ASSEMBLY.........................................................................................................................................695 REMOVAL,INSTALLATION OF REAR AXLE ASSEMBLY..........................................................................................................................................697 DISASSEMBLY,ASSEMBLY OF AXLE HOUSING ASSEMBLY.......................................................................................................................................700 DISASSEMBLY,ASSEMBLY OF DIFFERENTIAL ASSEMBLY.......................................................................................................................................713 REMOVAL,INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY...........................................................................................................................737 REMOVAL,INSTALLATION OF HST MOTOR 1 ASSEMBLY........................................................................................................................................740 REMOVAL,INSTALLATION OF HST MOTOR 2 ASSEMBLY........................................................................................................................................742 REMOVAL,INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY.......................................................................................................................744 REMOVAL,INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY(IF EQUIPPED)...................................................................................................................746 REMOVAL,INSTALLATION OF HYDRAULIC TANK ASSEMBLY.....................................................................................................................................748 REMOVAL,INSTALLATION OF WORK EQUIPMENT ASSEMBLY.....................................................................................................................................750 DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY.......................................................................................................................................757 DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY......................................................................................................................................784 DISASSEMBLY,ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.................................................................................................................................800 REMOVAL,INSTALLATION OF OPERATOR'S CAB ASSEMBLY.....................................................................................................................................807 REMOVAL,INSTALLATION OF OPERATOR'S CAB GLASS(STUCK GLASS)...........................................................................................................................813 REMOVAL,INSTALLATION OF CENTER HINGE PIN............................................................................................................................................821 REMOVAL,INSTALLATION OF COUNTERWEIGHT...............................................................................................................................................832 REMOVAL,INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...............................................................................................................................834 REMOVAL,INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY.........................................................................................................................837 REMOVAL,INSTALLATION OF MONITOR PANEL...............................................................................................................................................838 REMOVAL,INSTALLATION OF HST CONTROLLER ASSEMBLY.....................................................................................................................................842 90 OTHERS...............................................................................................................................................................................843 HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................................................................844 ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4)................................................................................................................................................845 ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4)................................................................................................................................................846 ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4)................................................................................................................................................847 ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4)................................................................................................................................................848 ELECTRICAL CIRCUIT DIAGRAM 2/4......................................................................................................................................................849 ELECTRICAL CIRCUIT DIAGRAM 3/4......................................................................................................................................................850 ELECTRICAL CIRCUIT DIAGRAM 4/4......................................................................................................................................................851 ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE) WA320-5........................................................................................................................................852 CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)..................................................................................................................................853
DESCRIPTION:
KOMATSU WA320-5 SHOP MANUAL SEBM0346-09 – PDF DOWNLOAD
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 chapters; these chapters are further divided into the each main group of components.
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together
S.S 25/12/24
