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Komatsu WA320-5 Wheel Loader Shop Manual SEBM034607 – PDF DOWNLOAD
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Komatsu WA320-5 Wheel Loader Shop Manual
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WA320-5 60001 and up
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Description
Komatsu WA320-5 Wheel Loader Shop Manual SEBM034607
FILE DETAILS:
Komatsu WA320-5 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA320-5
Serial Number: 60001 and up
Book Code: SEBM034607
Language: English
Pages: 823
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA320-5 Wheel Loader Shop Manual
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.
TABLE OF CONTENTS:
Komatsu WA320-5 Wheel Loader Shop Manual
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.......................................................................................................................................... 36 ENGINE MOUNT AND TRANSFER MOUNT..................................................................................................................................................... 37 DAMPER.............................................................................................................................................................................. 38 COOLING SYSTEM...................................................................................................................................................................... 39 POWER TRAIN......................................................................................................................................................................... 42 POWER TRAIN SYSTEM DIAGRAM.......................................................................................................................................................... 43 DRIVE SHAFT (PROPELLER SHAFT)....................................................................................................................................................... 45 HST HYDRAULIC PIPING DIAGRAM........................................................................................................................................................ 46 HST PUMP............................................................................................................................................................................ 47 HIGH-PRESSURE RELIEF VALVE.......................................................................................................................................................... 49 LOW-PRESSURE RELIEF VALVE........................................................................................................................................................... 51 HST CHARGE PUMP..................................................................................................................................................................... 52 SPEED-RELATED VALVE (DA VALVE)...................................................................................................................................................... 53 HIGH-PRESSURE CUT-OFF VALVE......................................................................................................................................................... 54 HST MOTOR........................................................................................................................................................................... 55 EP SERVO VALVE...................................................................................................................................................................... 58 HA SERVO VALVE...................................................................................................................................................................... 59 FORWARD-REVERSE SHUTTLE VALVE....................................................................................................................................................... 60 TRANSFER............................................................................................................................................................................ 61 CLUTCH SOLENOID VALVE............................................................................................................................................................... 72 AXLE................................................................................................................................................................................ 73 DIFFERENTIAL........................................................................................................................................................................ 75 LIMITED-SLIP DIFFERENTIAL........................................................................................................................................................... 82 FINAL DRIVE......................................................................................................................................................................... 86 AXLE MOUNTING AND CENTER HINGE PIN.................................................................................................................................................. 88 STEERING PIPING..................................................................................................................................................................... 93 STEERING COLUMN..................................................................................................................................................................... 94 PRIORITY VALVE...................................................................................................................................................................... 95 ORBIT-ROLL VALVE.................................................................................................................................................................... 98 CUSHION VALVE.......................................................................................................................................................................106 STEERING CYLINDER...................................................................................................................................................................107 EMERGENCY STEERING PIPING...........................................................................................................................................................109 EMERGENCY STEERING VALVE............................................................................................................................................................110 BRAKE PIPING........................................................................................................................................................................113 BRAKE VALVE.........................................................................................................................................................................114 INCHING VALVE.......................................................................................................................................................................118 CHARGE VALVE........................................................................................................................................................................119 ACCUMULATOR (FOR BRAKE).............................................................................................................................................................123 SLACK ADJUSTER......................................................................................................................................................................124 BRAKE...............................................................................................................................................................................126 PARKING BRAKE CONTROL...............................................................................................................................................................128 PARKING BRAKE.......................................................................................................................................................................129 HYDRAULIC PIPING....................................................................................................................................................................130 WORK EQUIPMENT LEVEL LINKAGE........................................................................................................................................................132 HYDRAULIC TANK......................................................................................................................................................................133 4-GEAR PUMP UNIT....................................................................................................................................................................135 ACCUMULATOR (FOR PPC CIRCUIT).......................................................................................................................................................137 LOCK VALVE..........................................................................................................................................................................138 E.C.S.S. VALVE......................................................................................................................................................................139 ACCUMULATOR (FOR E.C.S.S.)..........................................................................................................................................................141 HYDRAULIC PIPING OF COOLING SYSTEM..................................................................................................................................................142 COOLING FAN MOTOR...................................................................................................................................................................143 WORK EQUIPMENT CONTROL VALVE........................................................................................................................................................145 WORK EQUIPMENT PPC VALVE............................................................................................................................................................164 ATTACHMENT PPC VALVE................................................................................................................................................................176 WORK EQUIPMENT LINKAGE..............................................................................................................................................................180 BUCKET..............................................................................................................................................................................182 BUCKET POSITIONER AND BOOM KICK-OUT.................................................................................................................................................183 WORK EQUIPMENT CYLINDER.............................................................................................................................................................189 AIR CONDITIONER.....................................................................................................................................................................190 MACHINE MONITORING SYSTEM...........................................................................................................................................................191 MACHINE MONITOR.....................................................................................................................................................................200 LIST OF ITEMS DISPLAYED ON MONITOR..................................................................................................................................................201 ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)...........................................................................................................................................227 HST CONTROLLER......................................................................................................................................................................231 KOMTRAX SYSTEM......................................................................................................................................................................232 ENGINE START CIRCUIT................................................................................................................................................................234 ENGINE STOP CIRCUIT.................................................................................................................................................................236 PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)....................................................................................................................................237 PARKING BRAKE CIRCUIT...............................................................................................................................................................238 ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM.........................................................................................................................................241 SENSORS.............................................................................................................................................................................242 20 TESTING AND ADJUSTING................................................................................................................................................................250 STANDARD VALUE TABLE FOR ENGINE.....................................................................................................................................................251 STANDARD VALUE TABLE FOR CHASSIS....................................................................................................................................................252 TESTING AND ADJUSTING...............................................................................................................................................................256 TOOLS FOR TESTING, ADJUSTING,AND TROUBLESHOOTING................................................................................................................................257 MEASURING ENGINE SPEED..........................................................................................................................................................259 MEASURING EXHAUST GAS COLOR.....................................................................................................................................................260 ADJUSTING VALVE CLEARANCE.......................................................................................................................................................262 MEASURING COMPRESSION PRESSURE..................................................................................................................................................263 MEASURING BLOW-BY PRESSURE......................................................................................................................................................264 TESTING AND ADJUSTING FUEL INJECTION TIMING.....................................................................................................................................265 MEASURING ENGINE OIL PRESSURE...................................................................................................................................................266 MEASURING, TESTING OPERATION FORCE OF ACCELERATOR PEDAL.........................................................................................................................267 ADJUSTING ENGINE STOP SOLENOID..................................................................................................................................................269 ADJUSTING ENGINE SPEED SENSOR...................................................................................................................................................270 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...................................................................................................................270 MEASURING DIRECTIONAL LEVER.....................................................................................................................................................271 TESTING AND ADJUSTING HST OIL PRESSURE..........................................................................................................................................271 MEASURING CLUTCH CONTROL PRESSURE...............................................................................................................................................276 TESTING AND ADJUSTING STEERING WHEEL............................................................................................................................................277 TESTING AND ADJUSTING STEERING OIL PRESSURE.....................................................................................................................................278 BLEEDING AIR FROM STEERING CIRCUIT..............................................................................................................................................279 TESTING HYDRAULIC FAN...........................................................................................................................................................280 MEASURING BRAKE PEDAL...........................................................................................................................................................281 TESTING AND ADJUSTING BRAKE PEDAL LINKAGE.......................................................................................................................................282 MEASURING BRAKE PERFORMANCE.....................................................................................................................................................283 TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE...............................................................................................................................284 MEASURING BRAKE OIL PRESSURE....................................................................................................................................................285 MEASURING WEAR OF BRAKE DISC....................................................................................................................................................287 BLEEDING AIR FROM BRAKE CIRCUIT.................................................................................................................................................288 MEASURING PARKING BRAKE PERFORMANCE.............................................................................................................................................289 TESTING AND ADJUSTING PARKING BRAKE LINKAGE.....................................................................................................................................290 MEASURING AND ADJUSTING WORK EQUIPMENT CONTROL LEVER............................................................................................................................291 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE.........................................................................................................................292 TESTING AND ADJUSTING WORK EQUIPMENT PPC OIL PRESSURE...........................................................................................................................293 BLEEDING AIR....................................................................................................................................................................295 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT...............................................................................................................................296 TESTING AND ADJUSTING BUCKET POSITIONER.........................................................................................................................................296 TESTING AND ADJUSTING OF BOOM KICK-OUT..........................................................................................................................................298 CHECKING PROXIMITY SWITCH ACTUATION DISPLAY LAMP................................................................................................................................299 PROCEDURE FOR CHECKING DIODE....................................................................................................................................................300 METHOD OF CONNECTING T-ADAPTER FOR HST CONTROLLER...............................................................................................................................301 STARTING KOMTRAX TERMINAL OPERATIONS............................................................................................................................................302 SPECIAL FUNCTIONS OF MACHINE MONITOR............................................................................................................................................310 FLOW OF MODES AND FUNCTIONS.....................................................................................................................................................311 FAILURE CODE TABLE..............................................................................................................................................................319 PM CLINIC INSPECTION CHART......................................................................................................................................................329 TROUBLESHOOTING.....................................................................................................................................................................331 POINTS TO REMEMBER WHEN TROUBLESHOOTING.........................................................................................................................................332 SEQUENCE OF EVENTS IN TROUBLESHOOTING...........................................................................................................................................333 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.......................................................................................................................................334 CHECKS BEFORE TROUBLESHOOTING...................................................................................................................................................342 CATEGORIES,PROCEDURE,AND METHOD OF USING TROUBLESHOOTING CHARTS.................................................................................................................343 PHENOMENA CONSIDERED TO BE FAILURES AND TROUBLESHOOTING NO......................................................................................................................344 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS......................................................................................................................................347 T-ADAPTER TABLE.................................................................................................................................................................369 CONNECTOR TYPES AND MOUNTING LOCATIONS..........................................................................................................................................372 CONNECTOR LAYOUT DRAWING........................................................................................................................................................379 TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE).............................................................................................................................384 BEFORE TROUBLESHOOTING CODE DISPLAY.........................................................................................................................................385 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM....................................................................................................................................387 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................................................................388 FAILURE CODE [989F00] (HST MOTOR PROTECTION CAUTION(00))....................................................................................................................390 FAILURE CODE [DHH1KX] (HST OIL PRESSURE SENSOR INPUT SIGNAL OUTSIDE RANGE(KX))..............................................................................................391 FAILURE CODE [DLE2LC] (ENGINE REVOLUTION SENSOR REVOLUTION SPEED SIGNAL MISMATCH (LC))......................................................................................393 FAILURE CODE [DW26KZ] (MOTOR 2 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING(KZ)).......................................................................................394 FAILURE CODE [DX19KZ] (MOTOR 1 SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ))......................................................................................396 FAILURE CODE [DX20KZ] (CLUTCH SOLENOID SYSTEM DISCONTINUITY OR SHORT-CIRCUITING (KZ)).......................................................................................398 TROUBLESHOOTING CODE [HST-1](DEFECTIVE HST CONTROLLER POWER SOURCE (HST CONTROLLER DOES NOT FUNCTION))......................................................................400 TROUBLESHOOTING CODE [HST-2] (TRAVEL SPEED DOES NOT SHIFTED)................................................................................................................402 TROUBLESHOOTING CODE [HST-3] HST OUTPUT CONTROL(TRACTION CONTROL) CANNOT BE CONTROLLED......................................................................................405 TROUBLESHOOTING CODE [HSR-4] (TRAVEL SPEED LIMIT CANNOT BE CHANGED WHEN GEAR SPEED SELECTOR SWITCH IS IN "1ST" POSITION)....................................................407 TROUBLESHOOTING CODE [HST-5] (TRAVEL SPEED IS NOT INCREASED)................................................................................................................409 TROUBLESHOOTING OF TRAVEL DAMPER SYSTEM(ECSS MODE)..............................................................................................................................410 RELATED ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................................................411 ECSS-1 MALFUNCTION OF TRAVEL DAMPER.........................................................................................................................................412 TROUBLESHOOTING OF MONITOR SYSTEM(MON MODE).....................................................................................................................................417 BEFORE TROUBLESHOOTING CODE DISPLAY.........................................................................................................................................419 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM....................................................................................................................................421 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................................................................422 FAILURE CODE [15B0NX] (HST OIL FILTER CLOGGED (NX))........................................................................................................................424 FAILURE CODE [2G42ZG] (DECREASED BRAKE OIL PRESSURE(ZG))...................................................................................................................425 FAILURE CODE [989FOO] (HST MOTOR PROTECTION CAUTION (OO))...................................................................................................................426 FAILURE CODE [989FN1] (HST OVERRUNNING (N1))................................................................................................................................427 FAILURE CODE [AA1ANX] (CLOGGING OF AIR CLEANER (NX))........................................................................................................................428 FAILURE CODE [ABOOL6] (DEFECTIVE BATTERY CHARGING CIRCUIT(L6))..............................................................................................................430 FAILURE CODE [ABOOMA] (DEFECTIVE BATTERY CHARGING CIRCUIT (MA)).............................................................................................................431 FAILURE CODE [B@BAZG] (DEGREASED ENGINE OIL PRESSURE(ZG))...................................................................................................................432 FAILURE CODE [B@BAZK] LOWERING OF ENGINE OIL LEVEL(ZK)......................................................................................................................433 FAILURE CODE [B@BCNS] (ENGINE WATER TEMPERATURE OVERHEATING(NS))............................................................................................................434 FAILURE CODE [B@BCZK] (ALARM INDICATING LOW COOLANT LEVEL(ZK))..............................................................................................................435 FAILURE CODE [B@C7NS] (AXLE OIL TEMPERATURE OVERHEATING(NS))................................................................................................................436 FAILURE CODE [B@CRNS] (HST OIL TEMPERATURE OVERHEATING(NS)).................................................................................................................437 FAILURE CODE [D5ZHL6] (STARTING SWITCH "C"(IGN"C")INPUT FAILURE(L6))........................................................................................................438 FAILURE CODE [DAFOKT] (CONTROLLER INSIDE FAILURE(KT)).......................................................................................................................440 FAILURE CODE [DAJOKR] (HST CONTROLLER COMMUNICATION FAILURE(KR))............................................................................................................441 FAILURE CODE [DD15LD] (MONITOR PANEL MODE SELECTOR SWITCH 1[■](PANEL SWITCH 1)INPUT ERROR(LD))..............................................................................443 FAILURE CODE [DD16LD] (MONITOR PANEL MODE SELECTOR SWITCH 1[◇](PANEL SWITCH 2)INPUT ERROR (LD)..............................................................................444 FAILURE CODE [DD17LD] (MONITOR PANEL MODE SELECTOR SWITCH 2[<](PANEL SWITCH 3)INPUT ERROR (LD)..............................................................................445 FAILURE CODE [DD18LD] (MONITOR PANEL MODE SELECTOR SWITCH 2[>](PANEL SWITCH 4)INPUT ERROR (LD)..............................................................................446 FAILURE CODE [DDK3KB] (MULTIPLE DIRECTIONAL LEVER FR SIGNAL INPUT (KB)).....................................................................................................447 FAILURE CODE [DDS5L6] (DECREASED STEERING OIL PRESSURE(L6)).................................................................................................................449 FAILURE CODE [DGE2KX] (ENGINE WATER TEMPERATURE (HIGH TEMPERATURE) SENSOR SYSTEM FAILURE(KX))...............................................................................450 FAILURE CODE [DGE3L6] (ENGINE WATER TEMPERATURE (LOW TEMPERATURE)SENSOR SYSTEM FAILURE(L6)).................................................................................451 FAILURE CODE [DGH1LX] (HST OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX)).......................................................................................................452 FAILURE CODE [DGR4KA] (AXLE OIL TEMPERATURE SENSOR SYSTEM DISCONTINUITY(KA))................................................................................................453 FAILURE CODE [DGR4KX] (AXLE OIL TEMPERATURE SENSOR SYSTEM FAILURE(KX))......................................................................................................454 FAILURE CODE [DHE4L6] (ENGINE OIL PRESSURE SENSOR SYSTEM DISCONTINUITY(L6)).................................................................................................455 TROUBLESHOOTING CODE [MON-1] (THE PARKING BRAKE INDICATOR LAMP DOES NOT LIGHT ON)...........................................................................................456 TROUBLESHOOTING CODE [MON-2] (THE BRAKE OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON)........................................................................................460 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.) ....461 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.) ..............462 TROUBLESHOOTING CODE [MON-5] (THE FUEL LEVEL GAUGE DOES NOT RISE OR DECREASE.)..............................................................................................463 TROUBLESHOOTING CODE [MON-6] (THE RADIATOR COOLANT LEVEL CAUTION LAMP DOES NOT LIGHT ON)....................................................................................464 TROUBLESHOOTING CODE [MON-7] (THE STEERING OIL PRESSURE CAUTION LAMP DOES NOT LIGHT ON).....................................................................................465 TROUBLESHOOTING CODE [MON-6] (THE EMERGENCY STEERING OIL PRESSURE INDICATOR LAMP DOES NOT LIGHT ON).........................................................................466 TROUBLESHOOTING CODE [MON-9] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1[■](PANEL SWITCH 1)).....................................................................467 TROUBLESHOOTING CODE [MON-10] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 1[◇](PANEL SWITCH 2))....................................................................468 TROUBLESHOOTING CODE [MON-11] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2[<](PANEL SWITCH 3))....................................................................469 TROUBLESHOOTING CODE [MON-12] (INPUT FAILURE IN MONITOR PANEL MODE SELECTOR SWITCH 2[>](PANEL SWITCH 4))....................................................................470 TROUBLESHOOTING CODE [MON-13] (THE ALARM BUZZER DOES NOT SOUND OR STOP).....................................................................................................471 TROUBLESHOOTING CODE [MON-14] ENGINE OIL LEVEL CAUTION LAMP DOES NOT LIGHT UP...............................................................................................473 TROUBLESHOOTING CODE [MON-15] (AIR CLEANER CLOGGING INDICATOR LAMP DOES NOT LIGHT UP).......................................................................................474 TROUBLESHOOTING CODE [MON-16] THE WIPER DOES NOT FUNCTION...................................................................................................................476 TROUBLESHOOTING CODE [MON-17] (THE LAMPS DO NOT WORK PROPERLY)..............................................................................................................476 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)...................................................................................................................................477 BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM....................................................................................................................................478 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE..............................................................................................................................479 TROUBLESHOOTING CODE [E-1](THE ENGINE DOES NOT START).......................................................................................................................481 TROUBLESHOOTING CODE [E-2](THE ENGINE DOES NOT STOP)........................................................................................................................487 TROUBLESHOOTING CODE [E-3](PREHEATING IS IMPOSSIBLE OR CONSTANT)............................................................................................................489 TROUBLESHOOTING CODE [E-4](THE PARKING BRAKE (MECHANICAL TYPE) DOES NOT FUNCTION)...........................................................................................493 TROUBLESHOOTING CODE [E-5](DEFECTIVE BOOM KICK-OUT FUNCTION AND CANCELLATION)...............................................................................................498 TROUBLESHOOTING CODE [E-6](DEFECTIVE BUCKET POSITIONER FUNCTION AND CANCELLATION)...........................................................................................501 TROUBLESHOOTING CODE [E-7](DEFECTIVE LIFT ARM FLOATING HOLDING FUNCTION AND CANCELLATION)...................................................................................504 TROUBLESHOOTING CODE [E-8](TRAVEL DIRECTION IS NOT CHANGED NORMALLY)........................................................................................................505 TROUBLESHOOTING CODE [E-9](THE WIPER DOES NOT FUNCTION).....................................................................................................................511 TROUBLESHOOTING CODE [E-10](THE WINDOW WASHER DOES NOT FUNCTION)............................................................................................................516 TROUBLESHOOTING CODE [E-11](LAMPS DO NOT WORK PROPERLY).....................................................................................................................519 TROUBLESHOOTING CODE [E-12](THE HORN DOES NOT SOUND)........................................................................................................................530 TROUBLESHOOTING CODE [E-13](DEFECTIVE THE AIR CONDITIONER)..................................................................................................................532 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM(H MODE).........................................................................................................................544 METHOD OF USING TROUBLESHOOTING CHART.......................................................................................................................................545 FAILURE CODE AND CAUSE TABLE................................................................................................................................................547 H-1 THE MACHINE DOES NOT START..............................................................................................................................................549 H-2 THE TRAVEL SPEED IS SLOW................................................................................................................................................550 H-3 THE THRUSTING FORCE IS WEAK.............................................................................................................................................551 H-4 ENGINE STALLS WHEN TRAVELING OR ENGINE SPEED DROPS EXCESSIVELY..........................................................................................................552 H-5 THE GEAR IS NOT SHIFTED ................................................................................................................................................553 H-6 THE STEERING WHEEL DOES NOT TURN........................................................................................................................................554 H-7 THE STEERING WHEEL IS HEAVY.............................................................................................................................................555 H-8 STEERING WHEEL SHAKES OR JERKS..........................................................................................................................................556 H-10 THE BRAKE DOES NOT WORK OR NOES NOT WORK WELL .........................................................................................................................557 H-11 THE BRAKE IS NOT RELEASED OR IS DRAGGED................................................................................................................................558 H-12 THE LIFT ARM DOES NOT RISE OR LOWER....................................................................................................................................559 H-13 THE LIFT ARM MOVES SLOWLY OR THE LIFT ARM RISING FORCE IS INSUFFICIENT.................................................................................................560 H-14 WHEN RISING,THE LIFT ARM COMES TO MOVE SLOWLY AT SPECIFIC HEIGHT ......................................................................................................561 H-15 THE LIFT ARM CYLINDER CANNOT HOLD DOWN THE BUCKET(THE BUCKET RISES IN THE AIR).........................................................................................561 H-16 HYDRAULIC DRIFTS OF THE LIFT ARM OCCUR OFTEN...........................................................................................................................561 H-17 THE LIFT ARM WOBBLES DURING OPERATION..................................................................................................................................561 H-18 WHEN THE CONTROL LEVEL IS SWITCHED FROM "HOLD" TO "RAISE", THE LIFT ARM FALLS TEMPORARILY .............................................................................562 H-19 THE BUCKET DOES NOT TILT BACK..........................................................................................................................................563 H-20 THE BUCKET MOVES SLOWLY OR THE TILTING-BACK FORCE IS INSUFFICIENT......................................................................................................564 H-21 THE BUCKET COMES TO OPERATE SLOWLY IN HE MIDST OF TILTING BACK.........................................................................................................565 H-22 THE BUCKET CYLINDER CANNOT HOLD DOWN THE BUCKET........................................................................................................................565 H-23 HYDRAULIC DRIFTS OF THE BUCKET OCCUR OFTEN.............................................................................................................................565 H-24 THE BUCKET WOBBLES DURING TRAVEL WITH CARGO (THE WORK EQUIPMENT VALVE IS SET TO "HOLD")................................................................................566 H-25 WHEN THE CONTROL LEVEL IS SWITCHED FROM "HOLD"TO "TILT",THE BUCKET FALLS TEMPORARILY...................................................................................566 H-26 THE CONTROL LEVELS OF THE LIFT ARM AND BUCKET DO NOT MOVE SMOOTHLY AND HEAVY...........................................................................................566 H-27 THE TRAVEL DAMPER DOES NOT OPERATE AND MACHINE PITCHES AND BOUNCES.....................................................................................................567 TROUBLESHOOTING OF ENGINE (S MODE)..............................................................................................................................................568 METHOD OF USING TROUBLESHOOTING CHARTS .....................................................................................................................................569 S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)................................................................................................................573 S-2 ENGINE DOES NOT START...................................................................................................................................................575 (1)ENGINE DOES NOT TURN.................................................................................................................................................575 (2)ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT(FUEL IS NOT BEING INJECTED)..............................................................................................576 (3)EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED)............................................................................................577 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR).....................................................................................................................578 S-4 ENGINE STOPS DURING OPERATIONS..........................................................................................................................................579 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)................................................................................................................................580 S-6 ENGINE LACKS OUTPUT(OR LACKS POWER).....................................................................................................................................581 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)...........................................................................................................................582 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).................................................................................................................583 S-9 OIL BECOMES CONTAMINATED QUICKLY........................................................................................................................................584 S-10 FUEL CONSUMPTION IS EXCESSIVE..........................................................................................................................................585 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN..................................................................................................586 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE)..............................................................................................................587 S-13 OIL LEVEL RISES(WATER, FUEL IN OIL) ...................................................................................................................................588 S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING) .......................................................................................................................589 S-15 ABNORMAL NOISE IS MADE.................................................................................................................................................590 S-16 VIBRATION IS EXCESSIVE.................................................................................................................................................591 30 DISASSEMBLY AND ASSEMBLY.............................................................................................................................................................592 HOW TO READ THIS MANUAL.............................................................................................................................................................593 PRECAUTIONS WHEN CARRYING OUT OPERATION.............................................................................................................................................595 SPECIAL TOOL LIST...................................................................................................................................................................597 SKETCH OF SPECIAL TOOLS.............................................................................................................................................................600 REMOVAL,INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY................................................................................................................................606 REMOVAL,INSTALLATION OF NOZZLE HOLDER ASSEMBLY......................................................................................................................................610 REMOVAL,INSTALLATION OF CYLINDER HEAD ASSEMBLY......................................................................................................................................612 REMOVAL,INSTALLATION OF ENGINE ASSEMBLY.............................................................................................................................................620 REMOVAL,INSTALLATION OF RADIATOR ASSEMBLY...........................................................................................................................................627 REMOVAL,INSTALLATION OF AIR AFTERCOOLER.............................................................................................................................................628 REMOVAL,INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY...............................................................................................................................630 REMOVAL,INSTALLATION OF COOLING FAN AND FAN MOTOR ASSEMBLY..........................................................................................................................632 REMOVAL,INSTALLATION OF FUEL TANK ASSEMBLY..........................................................................................................................................634 REMOVAL,INSTALLATION OF TRANSFER....................................................................................................................................................636 DISASSEMBLY,ASSEMBLY OF TRANSFER ASSEMBLY...........................................................................................................................................638 REMOVAL,INSTALLATION OF PARKING BRAKE ASSEMBLY......................................................................................................................................658 DISASSEMBLY,ASSEMBLY OF PARKING BRAKE ASSEMBLY......................................................................................................................................660 REMOVAL,INSTALLATION OF FRONT AXLE ASSEMBLY.........................................................................................................................................665 REMOVAL,INSTALLATION OF REAR AXLE ASSEMBLY..........................................................................................................................................667 DISASSEMBLY,ASSEMBLY OF AXLE HOUSING ASSEMBLY.......................................................................................................................................670 DISASSEMBLY,ASSEMBLY OF DIFFERENTIAL ASSEMBLY.......................................................................................................................................683 REMOVAL,INSTALLATION OF HST PUMP AND 4-GEAR PUMP ASSEMBLY...........................................................................................................................707 REMOVAL,INSTALLATION OF HST MOTOR 1 ASSEMBLY........................................................................................................................................710 REMOVAL,INSTALLATION OF HST MOTOR 2 ASSEMBLY........................................................................................................................................712 REMOVAL,INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY.......................................................................................................................714 REMOVAL,INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY(IF EQUIPPED)...................................................................................................................716 REMOVAL,INSTALLATION OF HYDRAULIC TANK ASSEMBLY.....................................................................................................................................718 REMOVAL,INSTALLATION OF WORK EQUIPMENT ASSEMBLY.....................................................................................................................................720 DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY.......................................................................................................................................727 DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY......................................................................................................................................754 DISASSEMBLY,ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.................................................................................................................................770 REMOVAL,INSTALLATION OF OPERATOR'S CAB ASSEMBLY.....................................................................................................................................777 REMOVAL,INSTALLATION OF OPERATOR'S CAB GLASS(STUCK GLASS)...........................................................................................................................783 REMOVAL,INSTALLATION OF CENTER HINGE PIN............................................................................................................................................791 REMOVAL,INSTALLATION OF COUNTERWEIGHT...............................................................................................................................................802 REMOVAL,INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY...............................................................................................................................804 REMOVAL,INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY.........................................................................................................................807 REMOVAL,INSTALLATION OF MONITOR PANEL...............................................................................................................................................808 REMOVAL,INSTALLATION OF HST CONTROLLER ASSEMBLY.....................................................................................................................................812 90 OTHERS...............................................................................................................................................................................813 HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................................................................814 ELECTRICAL CIRCUIT DIAGRAM 1/4(1/4).................................................................................................................................................815 ELECTRICAL CIRCUIT DIAGRAM 1/4(2/4).................................................................................................................................................816 ELECTRICAL CIRCUIT DIAGRAM 1/4(3/4).................................................................................................................................................817 ELECTRICAL CIRCUIT DIAGRAM 1/4(4/4).................................................................................................................................................818 ELECTRICAL CIRCUIT DIAGRAM 2/4......................................................................................................................................................819 ELECTRICAL CIRCUIT DIAGRAM 3/4......................................................................................................................................................820 ELECTRICAL CIRCUIT DIAGRAM 4/4......................................................................................................................................................821 ELECTRICAL CIRCUIT DIAGRAM (A1 SIZE)................................................................................................................................................822 CONNECTORS TABLE AND ARRANGEMENT DRAWING (A1 SIZE)..................................................................................................................................823
KOMATSU WA320-5 WHEEL LOADER SHOP MANUAL SEBM034607 – PDF DOWNLOAD:
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Alfredo Kaleb –
If I get the manual it will have been great