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Description
KOMATSU WA320-5 SHOP MANUAL SEBM034612 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA320-5 SHOP MANUAL SEBM034612 – PDF DOWNLOAD
Language : English
Pages : 872
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA320-5 SHOP MANUAL SEBM034612 – 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..................................................................................................................................................................... 99 STEERING COLUMN.....................................................................................................................................................................100 PRIORITY VALVE......................................................................................................................................................................101 ORBIT-ROLL VALVE....................................................................................................................................................................104 CUSHION VALVE.......................................................................................................................................................................112 STEERING CYLINDER...................................................................................................................................................................113 EMERGENCY STEERING PIPING...........................................................................................................................................................115 EMERGENCY STEERING VALVE............................................................................................................................................................116 BRAKE PIPING........................................................................................................................................................................119 BRAKE VALVE.........................................................................................................................................................................120 INCHING VALVE.......................................................................................................................................................................124 CHARGE VALVE........................................................................................................................................................................126 ACCUMULATOR (FOR BRAKE).............................................................................................................................................................130 SLACK ADJUSTER......................................................................................................................................................................132 BRAKE...............................................................................................................................................................................134 PARKING BRAKE CONTROL...............................................................................................................................................................136 PARKING BRAKE.......................................................................................................................................................................137 HYDRAULIC PIPING....................................................................................................................................................................138 WORK EQUIPMENT LEVEL LINKAGE........................................................................................................................................................140 HYDRAULIC TANK......................................................................................................................................................................142 4-GEAR PUMP UNIT....................................................................................................................................................................144 ACCUMULATOR (FOR PPC CIRCUIT).......................................................................................................................................................146 LOCK VALVE..........................................................................................................................................................................147 E.C.S.S. VALVE......................................................................................................................................................................148 ACCUMULATOR (FOR E.C.S.S.)..........................................................................................................................................................150 HYDRAULIC PIPING OF COOLING SYSTEM..................................................................................................................................................151 COOLING FAN MOTOR...................................................................................................................................................................152 WORK EQUIPMENT CONTROL VALVE........................................................................................................................................................155 WORK EQUIPMENT PPC VALVE............................................................................................................................................................176 ATTACHMENT PPC VALVE................................................................................................................................................................188 WORK EQUIPMENT LINKAGE..............................................................................................................................................................192 BUCKET..............................................................................................................................................................................194 BUCKET POSITIONER AND BOOM KICK-OUT.................................................................................................................................................196 WORK EQUIPMENT CYLINDER.............................................................................................................................................................202 AIR CONDITIONER.....................................................................................................................................................................203 MACHINE MONITORING SYSTEM...........................................................................................................................................................204 MACHINE MONITOR.....................................................................................................................................................................214 LIST OF ITEMS DISPLAYED ON MONITOR..................................................................................................................................................215 ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)...........................................................................................................................................241 HST CONTROLLER......................................................................................................................................................................245 KOMTRAX SYSTEM......................................................................................................................................................................246 ENGINE START CIRCUIT................................................................................................................................................................248 ENGINE STOP CIRCUIT.................................................................................................................................................................250 PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)....................................................................................................................................251 PARKING BRAKE CIRCUIT...............................................................................................................................................................252 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM.........................................................................................................................................255 SENSORS.............................................................................................................................................................................256 20 TESTING AND ADJUSTING................................................................................................................................................................265 STANDARD VALUE TABLE FOR ENGINE.....................................................................................................................................................266 STANDARD VALUE TABLE FOR CHASSIS....................................................................................................................................................267 TESTING AND ADJUSTING...............................................................................................................................................................271 TOOLS FOR TESTING, ADJUSTING,AND TROUBLESHOOTING................................................................................................................................272 MEASURING ENGINE SPEED..........................................................................................................................................................274 MEASURING EXHAUST GAS COLOR.....................................................................................................................................................275 ADJUSTING VALVE CLEARANCE.......................................................................................................................................................277 MEASURING COMPRESSION PRESSURE..................................................................................................................................................278 MEASURING BLOW-BY PRESSURE......................................................................................................................................................279 TESTING AND ADJUSTING FUEL INJECTION TIMING.....................................................................................................................................280 MEASURING ENGINE OIL PRESSURE...................................................................................................................................................281 MEASURING, TESTING OPERATION FORCE OF ACCELERATOR PEDAL.........................................................................................................................282 ADJUSTING ENGINE STOP SOLENOID..................................................................................................................................................284 ADJUSTING ENGINE SPEED SENSOR...................................................................................................................................................285 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...................................................................................................................285 MEASURING DIRECTIONAL LEVER.....................................................................................................................................................286 TESTING AND ADJUSTING HST OIL PRESSURE..........................................................................................................................................286 MEASURING CLUTCH CONTROL PRESSURE...............................................................................................................................................291 TESTING AND ADJUSTING STEERING WHEEL............................................................................................................................................292 TESTING AND ADJUSTING STEERING OIL PRESSURE.....................................................................................................................................293 BLEEDING AIR FROM STEERING CIRCUIT..............................................................................................................................................294 TESTING HYDRAULIC FAN...........................................................................................................................................................295 MEASURING BRAKE PEDAL...........................................................................................................................................................296 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE.......................................................................................................................................297 MEASURING BRAKE PERFORMANCE.....................................................................................................................................................298 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE...............................................................................................................................299 MEASURING BRAKE OIL PRESSURE....................................................................................................................................................300 MEASURING WEAR OF BRAKE DISC....................................................................................................................................................302 BLEEDING AIR FROM BRAKE CIRCUIT.................................................................................................................................................303 MEASURING PARKING BRAKE PERFORMANCE.............................................................................................................................................304 TESTING AND ADJUSTING PARKING BRAKE LINKAGE.....................................................................................................................................305 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER............................................................................................................................306 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE.........................................................................................................................307 TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE...........................................................................................................................308 BLEEDING AIR....................................................................................................................................................................310 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...............................................................................................................................311 TESTING AND ADJUSTING BUCKET POSITIONER.........................................................................................................................................311 TESTING AND ADJUSTING OF BOOM KICK-OUT..........................................................................................................................................313 CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP................................................................................................................................314 PROCEDURE FOR CHECKING DIODE....................................................................................................................................................315 METHOD OF CONNECTING T-ADAPTER FOR HST CONTROLLER...............................................................................................................................316 STARTING KOMTRAX TERMINAL OPERATIONS............................................................................................................................................317 INDICATOR LAMPS OF KOMTRAX TERMINAL.............................................................................................................................................321 SPECIAL FUNCTIONS OF MACHINE MONITOR............................................................................................................................................325 FLOW OF MODES AND FUNCTIONS.....................................................................................................................................................326 FAILURE CODE TABLE..............................................................................................................................................................334 PM CLINIC INSPECTION CHART......................................................................................................................................................344 TROUBLESHOOTING.....................................................................................................................................................................347 POINTS TO REMEMBER WHEN TROUBLESHOOTING.........................................................................................................................................348 SEQUENCE OF EVENTS IN TROUBLESHOOTING...........................................................................................................................................349 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.......................................................................................................................................350 CHECKS BEFORE TROUBLESHOOTING...................................................................................................................................................358 CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................................359 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO......................................................................................................................360 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS......................................................................................................................................363 T-ADAPTER TABLE.................................................................................................................................................................386 CONNECTOR TYPES AND MOUNTING LOCATIONS..........................................................................................................................................389 CONNECTOR LAYOUT DRAWING........................................................................................................................................................396 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE).............................................................................................................................401 BEFORE TROUBLESHOOTING CODE DISPLAY.........................................................................................................................................402 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM....................................................................................................................................404 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................................................................405 FAILURE CODE [989F00] (HST MOTOR PROTECTION CAUTION(00))....................................................................................................................407 FAILURE CODE [DHH1KX] (HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE RANGE(KX))..............................................................................................408 FAILURE CODE [DLE2LC] (ENGINE REVOLUTION SENSOR REVOLUTION SPEED SIGNAL MISMATCH (LC))......................................................................................410 FAILURE CODE [DW26KZ] (MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING(KZ)).......................................................................................412 FAILURE CODE [DX19KZ] (MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))......................................................................................414 FAILURE CODE [DX20KZ] (CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)).......................................................................................416 TROUBLESHOOTING CODE [HST-1](DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))......................................................................418 TROUBLESHOOTING CODE [HST-2] (TRAVEL SPEED DOES NOT SHIFTED)................................................................................................................420 TROUBLESHOOTING CODE [HST-3] HST OUTPUT CONTROL(TRACTION CONTROL) CANNOT BE CONTROLLED......................................................................................424 TROUBLESHOOTING CODE [HSR-4] (TRAVEL SPEED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN "1ST" POSITION)....................................................426 TROUBLESHOOTING CODE [HST-5] (TRAVEL SPEED IS NOT INCREASED)................................................................................................................428 TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM(ECSS MODE)..............................................................................................................................429 RELATED ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................................................430 ECSS-1 MALFUNCTION OF TRAVEL DAMPER.........................................................................................................................................431 TROUBLESHOOTING OF MONITOR SYSTEM(MON MODE).....................................................................................................................................437 BEFORE TROUBLESHOOTING CODE DISPLAY.........................................................................................................................................440 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM....................................................................................................................................442 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................................................................443 FAILURE CODE [15B0NX] (HST OIL FILTER CLOGGED (NX))........................................................................................................................445 FAILURE CODE [2G42ZG] (DECREASED BRAKE OIL PRESSURE(ZG))...................................................................................................................446 FAILURE CODE [989FOO] (HST MOTOR PROTECTION CAUTION (OO))...................................................................................................................447 FAILURE CODE [989FN1] (HST OVERRUNNING (N1))................................................................................................................................448 FAILURE CODE [AA1ANX] (CLOGGING OF AIR CLEANER (NX))........................................................................................................................450 FAILURE CODE [ABOOL6] (DEFECTIVE BATTERY CHARGING CIRCUIT(L6))..............................................................................................................452 FAILURE CODE [ABOOMA] (DEFECTIVE BATTERY CHARGING CIRCUIT (MA)).............................................................................................................453 FAILURE CODE [B@BAZG] (DEGREASED ENGINE OIL PRESSURE(ZG))...................................................................................................................454 FAILURE CODE [B@BAZK] LOWERING OF ENGINE OIL LEVEL(ZK)......................................................................................................................455 FAILURE CODE [B@BCNS] (ENGINE WATER TEMPERATURE OVERHEATING(NS))............................................................................................................456 FAILURE CODE [B@BCZK] (ALARM INDICATING LOW COOLANT LEVEL(ZK))..............................................................................................................457 FAILURE CODE [B@C7NS] (AXLE OIL TEMPERATURE OVERHEATING(NS))................................................................................................................458 FAILURE CODE [B@CRNS] (HST OIL TEMPERATURE OVERHEATING(NS)).................................................................................................................459 FAILURE CODE [D5ZHL6] (STARTING SWITCH "C"(IGN"C")INPUT FAILURE(L6))........................................................................................................460 FAILURE CODE [DAFOKT] (CONTROLLER INSIDE FAILURE(KT)).......................................................................................................................462 FAILURE CODE [DAJOKR] (HST CONTROLLER COMMUNICATION FAILURE(KR))............................................................................................................464 FAILURE CODE [DD15LD] (MONITOR PANEL MODE SELECTOR SWITCH 1[■](PANEL SWITCH 1)INPUT ERROR(LD))..............................................................................466 FAILURE CODE [DD16LD] (MONITOR PANEL MODE SELECTOR SWITCH 1[◇](PANEL SWITCH 2)INPUT ERROR (LD)..............................................................................467 FAILURE CODE [DD17LD] (MONITOR PANEL MODE SELECTOR SWITCH 2[<](PANEL SWITCH 3)INPUT ERROR (LD)..............................................................................468 FAILURE CODE [DD18LD] (MONITOR PANEL MODE SELECTOR SWITCH 2[>](PANEL SWITCH 4)INPUT ERROR (LD)..............................................................................469 FAILURE CODE [DDK3KB] (MULTIPLE DIRECTIONAL LEVER FR SIGNAL INPUT (KB)).....................................................................................................470 FAILURE CODE [DDS5L6] (DECREASED STEERING OIL PRESSURE(L6)).................................................................................................................472 FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE (HIGH TEMPERATURE) SENSOR SYSTEM FAILURE(KX))...............................................................................473 FAILURE CODE [DGE3L6] (ENGINE WATER TEMPERATURE (LOW TEMPERATURE)SENSOR SYSTEM FAILURE(L6)).................................................................................474 FAILURE CODE [DGH1LX] (HST OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX)).......................................................................................................475 FAILURE CODE [DGR4KA] (AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY(KA))................................................................................................476 FAILURE CODE [DGR4KX] (AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))......................................................................................................477 FAILURE CODE [DHE4L6] (ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY(L6)).................................................................................................478 TROUBLESHOOTING CODE [MON-1] (THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)...........................................................................................480 TROUBLESHOOTING CODE [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)........................................................................................484 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.) ....485 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.) ..............486 TROUBLESHOOTING CODE [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.)..............................................................................................487 TROUBLESHOOTING CODE [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON)....................................................................................488 TROUBLESHOOTING CODE [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON).....................................................................................489 TROUBLESHOOTING CODE [MON-6] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON).........................................................................490 TROUBLESHOOTING CODE [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1[■](PANEL SWITCH 1)).....................................................................491 TROUBLESHOOTING CODE [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1[◇](PANEL SWITCH 2))....................................................................492 TROUBLESHOOTING CODE [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2[<](PANEL SWITCH 3))....................................................................493 TROUBLESHOOTING CODE [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2[>](PANEL SWITCH 4))....................................................................494 TROUBLESHOOTING CODE [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP).....................................................................................................496 TROUBLESHOOTING CODE [MON-14] ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT UP...............................................................................................498 TROUBLESHOOTING CODE [MON-15] (AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP).......................................................................................500 TROUBLESHOOTING CODE [MON-16] THE WIPER DOES NOT FUNCTION...................................................................................................................502 TROUBLESHOOTING CODE [MON-17] (THE LAMPS DO NOT WORK PROPERLY)..............................................................................................................502 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...................................................................................................................................503 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM....................................................................................................................................504 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................................................................505 TROUBLESHOOTING CODE [E-1](THE ENGINE DOES NOT START).......................................................................................................................508 TROUBLESHOOTING CODE [E-2](THE ENGINE DOES NOT STOP)........................................................................................................................514 TROUBLESHOOTING CODE [E-3](PREHEATING IS IMPOSSIBLE OR CONSTANT)............................................................................................................516 TROUBLESHOOTING CODE [E-4](THE PARKING BRAKE (MECHANICAL TYPE) DOES NOT FUNCTION)...........................................................................................520 TROUBLESHOOTING CODE [E-5](DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION)...............................................................................................526 TROUBLESHOOTING CODE [E-6](DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)...........................................................................................530 TROUBLESHOOTING CODE [E-7](DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION)...................................................................................533 TROUBLESHOOTING CODE [E-8](TRAVEL DIRECTION IS NOT CHANGED NORMALLY)........................................................................................................534 TROUBLESHOOTING CODE [E-9](THE WIPER DOES NOT FUNCTION).....................................................................................................................540 TROUBLESHOOTING CODE [E-10](THE WINDOW WASHER DOES NOT FUNCTION)............................................................................................................546 TROUBLESHOOTING CODE [E-11](LAMPS DO NOT WORK PROPERLY).....................................................................................................................550 TROUBLESHOOTING CODE [E-12](THE HORN DOES NOT SOUND)........................................................................................................................562 TROUBLESHOOTING CODE [E-13](DEFECTIVE THE AIR CONDITIONER)..................................................................................................................564 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM(H MODE).........................................................................................................................577 METHOD OF USING TROUBLESHOOTING CHART.......................................................................................................................................578 FAILURE CODE AND CAUSE TABLE................................................................................................................................................580 H-1 THE MACHINE DOES NOT START..............................................................................................................................................582 H-2 THE TRAVEL SPEED IS SLOW................................................................................................................................................583 H-3 THE THRUSTING FORCE IS WEAK.............................................................................................................................................584 H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY..........................................................................................................585 H-5 THE GEAR IS NOT SHIFTED ................................................................................................................................................586 H-6 THE STEERING WHEEL DOES NOT TURN........................................................................................................................................587 H-7 THE STEERING WHEEL IS HEAVY.............................................................................................................................................588 H-8 STEERING WHEEL SHAKES OR JERKS..........................................................................................................................................589 H-10 THE BRAKE DOES NOT WORK OR NOES NOT WORK WELL .........................................................................................................................590 H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED................................................................................................................................591 H-12 THE LIFT ARM DOES NOT RISE OR LOWER....................................................................................................................................592 H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT.................................................................................................593 H-14 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT ......................................................................................................594 H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET(THE BUCKET RISES IN THE AIR).........................................................................................594 H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN...........................................................................................................................594 H-17 THE LIFT ARM WOBBLES DURING OPERATION..................................................................................................................................594 H-18 WHEN THE CONTROL LEVEL IS SWITCHED FROM "HOLD" TO "RAISE", THE LIFT ARM FALLS TEMPORARILY .............................................................................595 H-19 THE BUCKET DOES NOT TILT BACK..........................................................................................................................................596 H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT......................................................................................................597 H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING BACK.........................................................................................................598 H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET........................................................................................................................598 H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN.............................................................................................................................598 H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO "HOLD")................................................................................599 H-25 WHEN THE CONTROL LEVEL IS SWITCHED FROM "HOLD"TO "TILT",THE BUCKET FALLS TEMPORARILY...................................................................................599 H-26 THE CONTROL LEVELS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY...........................................................................................599 H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES.....................................................................................................600 TROUBLESHOOTING OF ENGINE (S MODE)..............................................................................................................................................601 METHOD OF USING TROUBLESHOOTING CHARTS .....................................................................................................................................602 S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)................................................................................................................606 S-2 ENGINE DOES NOT START...................................................................................................................................................608 (1)ENGINE DOES NOT TURN.................................................................................................................................................608 (2)ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED)..............................................................................................609 (3)EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED)............................................................................................610 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR).....................................................................................................................611 S-4 ENGINE STOPS DURING OPERATIONS..........................................................................................................................................612 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)................................................................................................................................613 S-6 ENGINE LACKS OUTPUT(OR LACKS POWER).....................................................................................................................................614 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)...........................................................................................................................615 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).................................................................................................................616 S-9 OIL BECOMES CONTAMINATED QUICKLY........................................................................................................................................617 S-10 FUEL CONSUMPTION IS EXCESSIVE..........................................................................................................................................618 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN..................................................................................................619 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)..............................................................................................................620 S-13 OIL LEVEL RISES(WATER, FUEL IN OIL) ...................................................................................................................................621 S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING) .......................................................................................................................622 S-15 ABNORMAL NOISE IS MADE.................................................................................................................................................623 S-16 VIBRATION IS EXCESSIVE.................................................................................................................................................624 30 DISASSEMBLY AND ASSEMBLY.............................................................................................................................................................625 How to read this manual.............................................................................................................................................................626 Precautions when carrying out operation.............................................................................................................................................628 Special tool list...................................................................................................................................................................630 Sketch of special tools.............................................................................................................................................................633 Removal, installation of fuel injection pump assembly...............................................................................................................................640 Removal, installation of nozzle holder assembly.....................................................................................................................................644 Removal, installation of cylinder head assembly.....................................................................................................................................646 Removal, installation of engine assembly............................................................................................................................................654 Removal, installation of radiator assembly..........................................................................................................................................661 Removal, installation of air aftercooler............................................................................................................................................662 Removal, installation of hydraulic oil cooler assembly..............................................................................................................................664 Removal, installation of cooling fan and fan motor assembly.........................................................................................................................666 Removal, installation of fuel tank assembly.........................................................................................................................................668 Removal, installation of transfer...................................................................................................................................................670 Disassembly, assembly of transfer assembly..........................................................................................................................................672 Removal, installation of parking brake assembly.....................................................................................................................................692 Disassembly, assembly of parking brake assembly.....................................................................................................................................694 Removal, installation of front axle assembly........................................................................................................................................699 Removal, installation of rear axle assembly.........................................................................................................................................701 Disassembly, assembly of axle housing assembly......................................................................................................................................704 Disassembly, assembly of differential assembly......................................................................................................................................717 Removal, installation of HST pump and 4-gear pump assembly..........................................................................................................................743 Removal, installation of HST motor 1 assembly.......................................................................................................................................746 Removal, installation of HST motor 2 assembly.......................................................................................................................................748 Removal, installation of work equipment control valve assembly......................................................................................................................750 Removal, installation of travel damper valve assembly (If equipped).................................................................................................................752 Removal, installation of hydraulic tank assembly....................................................................................................................................754 Removal, installation of work equipment assembly....................................................................................................................................756 Disassembly and assembly of HST pump assembly.......................................................................................................................................763 Disassembly and assembly of HST motor assembly......................................................................................................................................790 Disassembly, assembly of hydraulic cylinder assembly................................................................................................................................806 Removal, installation of operator's cab assembly....................................................................................................................................813 Removal, installation of operator's cab glass (Stuck glass).........................................................................................................................819 Removal, installation of center hinge pin...........................................................................................................................................827 Removal, installation of counterweight..............................................................................................................................................840 Removal, installation of air conditioner unit assembly..............................................................................................................................842 Removal, installation of air conditioner compressor assembly........................................................................................................................845 Removal, installation of monitor panel..............................................................................................................................................846 Removal, installation of HST controller assembly....................................................................................................................................850 90 OTHERS...............................................................................................................................................................................851 HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................................................................853 ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4).................................................................................................................................................855 ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4).................................................................................................................................................857 ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4).................................................................................................................................................859 ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4).................................................................................................................................................861 ELECTRICAL CIRCUIT DIAGRAM 2/4......................................................................................................................................................863 ELECTRICAL CIRCUIT DIAGRAM 3/4......................................................................................................................................................865 ELECTRICAL CIRCUIT DIAGRAM 4/4......................................................................................................................................................867 ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)................................................................................................................................................869 CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)..................................................................................................................................871
DESCRIPTION:
KOMATSU WA320-5 SHOP MANUAL SEBM034612 – PDF DOWNLOAD
FOREWORD
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.
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