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Komatsu Wheel Loader WA320-1LC Service Repair Manual – PDF DOWNLOAD
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Description
Komatsu Wheel Loader WA320-1LC Service Repair Manual
FILE DETAILS:
Komatsu Wheel Loader WA320-1LC Service Repair Manual
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBMW19020
Total Pages : 640
DESCRIPTION:
Komatsu Wheel Loader WA320-1LC Service Repair Manual
FOREWORD:
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 chapters for each main group of components; these chapters are further divided into the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu Wheel Loader WA320-1LC Service Repair Manual
MAIN MENU.................................................................................................. 0 CONTENTS................................................................................................... 7 10 ENGINE.................................................................................................. 21 12 TESTING AND ADJUSTING............................................................................... 21 STANDARD VALUE TABLE .............................................................................. 22 TOOL LIST FOR TESTING AND ADJUSTING ............................................................... 25 VALVE CLEARANCE.................................................................................... 27 FUEL INJECTION TIMING ............................................................................. 28 ENGINE OIL PRESSURE AND TEMPERATURE .............................................................. 29 BLOW-BY PRESSURE .................................................................................. 31 EXHAUST GAS COLOR ................................................................................. 32 ACCELERATOR PEDAL, OPERATING FORCE AND OPERATING ANGLE ........................................... 33 13 DISASSEMBLY AND ASSEMBLY............................................................................ 37 STARTING MOTOR .................................................................................... 39 REMOVAL........................................................................................ 39 INSTALLATION................................................................................... 39 ALTERNATOR ........................................................................................ 40 REMOVAL........................................................................................ 40 INSTALLATION................................................................................... 40 OIL COOLER......................................................................................... 41 REMOVAL........................................................................................ 41 INSTALLATION................................................................................... 41 FUEL INJECTION PUMP................................................................................ 42 REMOVAL........................................................................................ 42 INSTALLATION................................................................................... 42 WATER PUMP......................................................................................... 43 REMOVAL........................................................................................ 43 INSTALLATION................................................................................... 43 INJECTORS.......................................................................................... 44 REMOVAL........................................................................................ 44 INSTALLATION................................................................................... 45 TURBOCHARGER ...................................................................................... 46 REMOVAL........................................................................................ 46 INSTALLATION................................................................................... 47 CYLINDER HEAD...................................................................................... 48 REMOVAL........................................................................................ 48 INSTALLATION................................................................................... 49 RADIATOR .......................................................................................... 50 REMOVAL........................................................................................ 50 INSTALLATION................................................................................... 52 ENGINE............................................................................................. 54 REMOVAL........................................................................................ 54 INSTALLATION................................................................................... 59 FUEL TANK ......................................................................................... 64 REMOVAL ....................................................................................... 64 INSTALLATION................................................................................... 65 14 MAINTENANCE STANDARD................................................................................ 67 ENGINE MOUNT ...................................................................................... 68 RADIATOR AND TORQUE CONVERTER OIL COOLER .......................................................... 69 20 POWER TRAIN............................................................................................. 71 21 STRUCTURE AND FUNCTION.............................................................................. 71 GENERAL............................................................................................ 72 HYDRAULIC CIRCUIT FOR POWER TRAIN.............................................................. 76 HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN...................................................... 77 TORQUE CONVERTER AND TRANSMISSION PIPING........................................................... 78 TORQUE CONVERTER CHARGING PUMP .................................................................... 79 TORQUE CONVERTER................................................................................... 80 TORQUE CONVERTER OIL FILTER........................................................................ 81 TRANSMISSION ...................................................................................... 82 CLUTCH PACK.................................................................................... 84 FORWARD AND REVERSE CLUTCH................................................................. 84 1ST, 3RD CLUTCH............................................................................ 84 2ND, 4TH CLUTCH............................................................................ 85 CONTROL VALVE.................................................................................. 86 SOLENOID VALVE................................................................................. 87 UPPER VALVE.................................................................................... 88 LOWER VALVE.................................................................................... 89 PRIORITY AND MAIN REGULATOR VALVE.............................................................. 90 MAIN REGULATOR VALVE........................................................................... 91 TORQUE CONVERTER OIL OUTLET VALVE.............................................................. 92 PILOT REDUCING VALVE........................................................................... 93 SOLENOID VALVE................................................................................. 94 FILL VALVE..................................................................................... 95 MODULATING RELIEF VALVE, ACCUMULATOR VALVE, QUICK RETURN VALVE................................. 97 DIRECTIONAL SPOOL..............................................................................101 EMERGENCY MANUAL SPOOL.........................................................................102 PILOT OIL FILTER...............................................................................103 AXLE MOUNT.........................................................................................104 AXLE...............................................................................................106 FRONT..........................................................................................106 REAR...........................................................................................107 DIFFERENTIAL.......................................................................................108 FINAL DRIVE........................................................................................109 TIRE AND WHEEL.....................................................................................110 22 TESTING AND ADJUSTING...............................................................................111 STANDARD VALUE TABLE ..............................................................................112 TOOL LIST FOR TESTING AND ADJUSTING ...............................................................113 ENGINE STALL SPEED.................................................................................114 MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION........................................116 SHIFT LEVER .......................................................................................119 METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL ...................................................120 TIRE AND WHEEL.....................................................................................122 TROUBLESHOOTING....................................................................................123 PRECAUTIONS WHEN TROUBLESHOOTING...............................................................124 METHOD OF READING TROUBLESHOOTING TABLES.......................................................126 PREVENTING RECURRENCE OF TROUBLE...............................................................128 CHECKS BEFORE TROUBLESHOOTING..................................................................129 JUDGEMENT ON POWER TRAIN.......................................................................130 TROUBLESHOOTING TABLE..........................................................................132 1. Machine does not move.......................................................................132 2. Machine speed is low, thrust is weak, gradeability falls off................................134 3. Large shock when moving off or changing gear................................................136 4. Large time lag when moving off or changing gear.............................................137 5. Oil temperature in torque converter is high.................................................138 23 DISASSEMBLY AND ASSEMBLY ...........................................................................139 TORQUE CONVERTER CHARGING PUMP ....................................................................141 REMOVAL........................................................................................141 INSTALLATION...................................................................................141 TRANSMISSION, TORQUE CONVERTER ...................................................................142 REMOVAL........................................................................................142 INSTALLATION...................................................................................148 TORQUE CONVERTER ..................................................................................154 DISASSEMBLY ...................................................................................154 ASSEMBLY.......................................................................................157 TRANSMISSION.......................................................................................160 DISASSEMBLY....................................................................................160 ASSEMBLY.......................................................................................167 CLUTCH PACK........................................................................................178 DISASSEMBLY....................................................................................178 FORWARD-REVERSE CLUTCH PACK................................................................178 1ST-3RD SPEED CLUTCH PACK..................................................................180 2ND-4TH SPEED CLUTCH PACK..................................................................182 ASSEMBLY.......................................................................................184 FORWARD-REVERSE CLUTCH PACK................................................................185 1ST-3RD SPEED CLUTCH PACK..................................................................190 2ND-4TH SPEED CLUTCH PACK..................................................................194 TRANSMISSION CONTROL VALVE ........................................................................198 REMOVAL .......................................................................................198 INSTALLATION...................................................................................199 TRANSMISSION SOLENOID VALVE........................................................................205 DISASSEMBLY....................................................................................205 ASSEMBLY.......................................................................................205 DIFFERENTIAL.......................................................................................206 DISASSEMBLY....................................................................................206 ASSEMBLY.......................................................................................210 FRONT AXLE.........................................................................................221 REMOVAL........................................................................................221 INSTALLATlON...................................................................................223 REAR AXLE .........................................................................................225 REMOVAL........................................................................................225 INSTALLATION...................................................................................228 DRIVE SHAFT .......................................................................................231 DISASSEMBLY....................................................................................231 ASSEMBLY.......................................................................................233 AXLE HOUSING ......................................................................................235 DISASSEMBLY....................................................................................235 ASSEMBLY.......................................................................................240 24 MAINTENANCE STANDARD ...............................................................................247 ENGINE AND TRANSMISSION MOUNT......................................................................248 TORQUE CONVERTER CHARGING PUMP ....................................................................250 TORQUE CONVERTER...................................................................................251 TRANSMISSION.......................................................................................252 TRANSMISSION CONTROL VALVE.........................................................................255 UPPER VALVE....................................................................................255 LOWER VALVE....................................................................................257 SOLENOID VALVE.....................................................................................258 TRANSMISSION CLUTCH................................................................................259 DIFFERENTIAL.......................................................................................262 FINAL DRIVE........................................................................................264 DRIVE SHAFT........................................................................................266 AXLE MOUNT.........................................................................................267 AXLE...............................................................................................269 40 STEERING SYSTEM.........................................................................................273 41 STRUCTURE AND FUNCTION..............................................................................273 HYDRAULIC PIPING...................................................................................274 HYDRAULIC CIRCUIT SCHEMATICS.......................................................................274 HYDRAULIC CIRCUIT DIAGRAM..........................................................................276 2-SPOOL........................................................................................276 3-SPOOL (WITH GROUND STEERING) DRJEN...........................................................277 3-SPOOL (WITH GROUND DRIVEN STEERING, SECURITY VALVE)..........................................278 STEERING CONTROL SYSTEM ...........................................................................279 STEERING VALVE (ORBITROL VALVE) ...............................................................279 PRIORITY VALVE.................................................................................286 HAND PUMP AND SLEEVE...........................................................................289 CUSHION VALVE..................................................................................291 GROUND DRIVEN STEERING PUMP....................................................................292 DIVERTER VALVE.................................................................................293 STEERING COLUMN ...................................................................................296 STEERING CYLINDER MOUNT AND CENTER HINGE PIN ......................................................297 42 TESTING AND ADJUSTING...............................................................................299 STANDARD VALUE TABLE FOR CHASSIS...................................................................300 TOOL LIST..........................................................................................300 STEERING WHEEL.....................................................................................301 PLAY...........................................................................................301 OPERATING FORCE................................................................................302 OPERATING TIME - LOCK TO LOCK..................................................................303 STEERING OIL PRESSURE..............................................................................304 TROUBLESHOOTING....................................................................................305 STEERING SYSTEM................................................................................306 1. Steering wheel does not turn................................................................306 2. Steering wheel is sluggish..................................................................307 3. Steering wheel moves unsteadily or is subjected to large shock..............................308 43 DISASSEMBLY AND ASSEMBLY............................................................................309 STEERING VALVE.....................................................................................310 REMOVAL........................................................................................310 INSTALLATION...................................................................................312 DISASSEMBLY....................................................................................315 ASSEMBLY.......................................................................................318 PRIORITY VALVE.....................................................................................323 REMOVAL........................................................................................323 INSTALLATION...................................................................................325 STEERING CYLINDER..................................................................................327 REMOVAL........................................................................................327 INSTALLATION...................................................................................328 DISASSEMBLY....................................................................................329 ASSEMBLY.......................................................................................331 CENTER HINGE PIN...................................................................................334 REMOVAL........................................................................................334 INSTALLATlON...................................................................................339 44 MAINTENANCE STANDARD................................................................................345 STEERING COLUMN ...................................................................................346 STEERING CYLINDER MOUNT............................................................................347 CENTER HINGE PIN...................................................................................347 STEERING PUMP......................................................................................350 PRIORITY VALVE.....................................................................................351 GROUND DRIVEN STEERING.............................................................................352 50 BRAKE SYSTEM............................................................................................353 51 STRUCTURE AND FUNCTION..............................................................................353 BRAKE CONTROL SYSTEM...............................................................................354 SYSTEM DIAGRAM.................................................................................354 BRAKE CIRCUIT DIAGRAM..........................................................................355 BRAKE CIRCUIT SCHEMATICS.......................................................................356 CHARGE VALVE.......................................................................................357 ACCUMULATOR........................................................................................361 BRAKE VALVE........................................................................................362 PRESSURE CONTROL VALVE.........................................................................363 SAFETY VALVE...................................................................................364 BRAKE..............................................................................................365 PARKING BRAKE......................................................................................366 BRAKE CALIPER......................................................................................367 52 TESTING AND ADJUSTING...............................................................................369 STANDARD VALUE TABLE...............................................................................370 TOOL LIST..........................................................................................371 BRAKE PEDAL........................................................................................372 BRAKE PEDAL LINKAGE................................................................................373 BRAKE PERFORMANCE..................................................................................374 BRAKE PISTON LEAKAGE...............................................................................375 BRAKE DISC.........................................................................................376 AIR BLEEDING.......................................................................................377 ACCUMULATOR CIRCUIT............................................................................377 FRONT AXLE BRAKE CIRCUIT.......................................................................378 REAR AXLE BRAKE CIRCUIT........................................................................378 PARKING BRAKE......................................................................................379 PERFORMANCE....................................................................................379 CHECKING AND ADJUSTING.........................................................................380 CLEARANCE......................................................................................382 53 DISASSEMBLY AND ASSEMBLY............................................................................383 BRAKE VALVE........................................................................................384 REMOVAL........................................................................................384 INSTALLATION...................................................................................385 DISASSEMBLY....................................................................................386 ASSEMBLY.......................................................................................387 PARKING BRAKE......................................................................................388 REMOVAL........................................................................................388 INSTALLATION...................................................................................390 PARKING BRAKE PAD..................................................................................392 REMOVAL........................................................................................392 INSTALLATION...................................................................................392 ACCUMULATOR........................................................................................393 REMOVAL........................................................................................393 INSTALLATION...................................................................................393 DISASSEMBLY....................................................................................394 ASSEMBLY.......................................................................................394 54 MAINTENANCE STANDARD................................................................................397 BRAKE..............................................................................................398 PARKING BRAKE......................................................................................399 BRAKE VALVE........................................................................................400 60 WORK EQUIPMENT SYSTEM...................................................................................401 61 STRUCTURE AND FUNCTION..............................................................................401 HYDRAULIC PIPING...................................................................................402 HYDRAULIC CIRCUIT DIAGRAMS.........................................................................403 HYDRAULIC TANK.....................................................................................405 OIL FILTER BYPASS VALVE........................................................................406 BREATHER.......................................................................................407 HYDRAULIC AND STEERING PUMPS.......................................................................408 HYDRAULIC VALVES...................................................................................409 SECURITY VALVE.................................................................................409 PRIORITY VALVE.................................................................................410 RELIEF VALVE...................................................................................411 SAFETY VALVE (WITH SUCTION VALVE)..............................................................412 SUCTION VALVE..................................................................................413 MAIN CONTROL VALVE.............................................................................414 2-SPOOL....................................................................................414 3-SPOOL....................................................................................416 OPERATION..................................................................................418 HYDRAULIC CYLINDER.................................................................................424 LIFT CYLINDER..................................................................................424 DUMP CYLINDER..................................................................................424 STEERING CYLINDER..............................................................................424 BUCKET LINKAGE.....................................................................................425 WORK EQUIPMENT LEVER LINKAGE.......................................................................427 62 TESTING AND ADJUSTING...............................................................................429 STANDARD VALUE TABLE ..............................................................................431 TOOL LIST..........................................................................................432 DUMP AND LIFT CONTROL LEVERS ......................................................................433 HYDRAULIC CIRCUIT FLUSHING ........................................................................435 HYDRAULIC PRESSURE ................................................................................438 LIFT ARM AND BUCKET ...............................................................................440 HYDRAULIC DRIFT OF LIFT ARM AND BUCKET ...........................................................442 BUCKET POSITIONER..................................................................................443 BOOM KICK-OUT .....................................................................................445 TROUBLESHOOTING....................................................................................447 TROUBLESHOOTING TABLES.........................................................................448 1. Lift arm does not rise......................................................................448 2. Lift arm moves slowly or does not have sufficient lifting power.............................449 3. Lift arm movement becomes slow after it reaches a certain height............................450 4. Bucket cannot be held down with lift arm cylinder...........................................450 5. Lift arm has large hydraulic drift..........................................................450 6. Lift arm movement is unsteady during work...................................................450 7. Lift arm descends momentarily when control lever is shifted from "Hold" to "Raise"..........450 8. Bucket does not tilt back...................................................................451 9. Bucket moves slowly or has insufficient tilt back power.....................................452 10. Bucket movement becomes slow during tilt back..............................................453 11. Bucket cannot be held down by the dump cylinder............................................453 12. Bucket has large hydraulic drift...........................................................453 13. Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold")....453 14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back"..........453 15. Control levers of lift arm and bucket move stiffly and sluggishly..........................454 63 DISASSEMBLY AND ASSEMBLY............................................................................455 HYDRAULIC TANK ....................................................................................456 REMOVAL........................................................................................456 INSTALLATION...................................................................................459 HYDRAULIC FILTER ..................................................................................461 REMOVAL........................................................................................461 INSTALLATION...................................................................................461 HYDRAULIC & STEERING PUMP..........................................................................462 REMOVAL........................................................................................462 INSTALLATION...................................................................................463 MAIN CONTROL VALVE ................................................................................464 REMOVAL........................................................................................464 INSTALLATION...................................................................................466 DISASSEMBLY....................................................................................467 ASSEMBLY.......................................................................................469 DUMP CYLINDER......................................................................................471 REMOVAL........................................................................................471 INSTALLATION...................................................................................473 LlFT CYLINDER......................................................................................474 REMOVAL........................................................................................474 INSTALLATION...................................................................................475 HYDRAULIC CYLINDER.................................................................................476 DISASSEMBLY....................................................................................476 ASSEMBLY.......................................................................................478 WORK EQUIPMENT.....................................................................................481 REMOVAL........................................................................................481 INSTALLATION...................................................................................484 COUNTERWEIGHT......................................................................................487 REMOVAL........................................................................................487 INSTALLATION...................................................................................487 64 MAINTENANCE STANDARD................................................................................489 HYDRAULIC AND STEERING PUMPS.......................................................................490 GROUND DRIVEN STEERING PUMP........................................................................491 PRIORITY VALVE.....................................................................................492 MAIN CONTROL VALVE.................................................................................494 2-SPOOL........................................................................................494 3-SPOOL........................................................................................496 CYLINDER...........................................................................................498 STEERING CYLINDER..............................................................................498 LIFT CYLINDER..................................................................................498 DUMP CYLINDER..................................................................................498 BUCKET LINKAGE.....................................................................................500 BUCKET.............................................................................................504 WITH TOOTH.....................................................................................504 WITH B.O.C.....................................................................................504 BUCKET POSITIONER AND BOOM KICK-OUT................................................................505 80 ELECTRIC AND ELECTRONIC SYSTEM..........................................................................507 81 STRUCTURE AND FUNCTION..............................................................................507 ELECTRICAL FOLDOUT.................................................................................508 ENGINE STARTING CIRCUIT............................................................................509 SAFETY RELAY.......................................................................................510 ENGINE STOP CIRCUIT................................................................................511 ELECTRICAL TRANSMISSION CONTROL....................................................................512 COMBINATION SWITCH.............................................................................513 TRANSMISSION CUT-OFF SELECTOR SWITCH...........................................................514 NEUTRALIZER RELAY..............................................................................515 KICK-DOWN SWITCH...................................................................................516 KICK-DOWN ELECTRICAL CIRCUIT.......................................................................517 BUCKET POSITIONER AND BOOM KICK-OUT................................................................525 PROXIMITY SWITCH...................................................................................527 ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)........................................................531 MONITOR PANEL..................................................................................532 INDICATION ON MONITOR PANEL....................................................................533 SENSORS, SWITCHES..............................................................................535 SENSOR, SWITCH ACTUATION TABLE.............................................................535 BRAKE PRESSURE SWITCH......................................................................536 BRAKE DIFFERENTIAL PRESSURE WARNING SWITCH.................................................536 COOLANT LEVEL SENSOR.......................................................................537 TORQUE CONVERTER OIL TEMPERATURE SENSOR....................................................537 ROTATIONAL SPEED SENSOR....................................................................538 FUEL LEVEL SENSOR..........................................................................539 82 TESTING AND ADJUSTING...............................................................................541 SPEEDOMETER MODULE.................................................................................543 TROUBLESHOOTING....................................................................................545 PRECAUTION WHEN HANDLING CONNECTOR.............................................................546 CONNECTOR TERMINAL NUMBERS.....................................................................548 POSITION OF CONNECTORS FOR TROUBLESHOOTING.................................................553 ELECTRICAL CIRCUIT SYSTEM......................................................................558 ENGINE STARTING CIRCUIT SYSTEM.............................................................558 ENGINE STOP CIRCUIT SYSTEM.................................................................559 TRANSMISSION CONTROL AND PARKING BRAKE SYSTEM..............................................560 ELECTRICAL CN AND THREE DIMENSIONAL VIEW DIAGRAM...............................................561 METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART..............................................562 TROUBLESHOOTING TABLES.........................................................................565 E-1 ENGINE DOES NOT START..................................................................566 E-2 ENGINE DOES NOT STOP...................................................................567 E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING.................................................567 E-4 TRANSMISSION DOES NOT RETURN TO NEUTRAL................................................568 E-5 TRANSMISSION DOES NOT WORK NORMALLY....................................................569 E-6 KICK-DOWN SWITCH DOES NOT WORK.........................................................588 E-7 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON.......................................590 E-8 KICK-DOWN OPERATION IS NOT CANCELED....................................................591 E-9 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2........................................592 83 DISASSEMBLY AND ASSEMBLY............................................................................593 MACHINE MONITOR....................................................................................594 REMOVAL........................................................................................594 INSTALLATION...................................................................................595 90 OTHER...................................................................................................597 93 DISASSEMBLY AND ASSEMBLY............................................................................597 CAB................................................................................................598 REMOVAL........................................................................................598 INSTALLATION...................................................................................598 CAB................................................................................................599 97 GEAR PUMP...........................................................................................601 GENERAL............................................................................................602 PRINCIPLE OF OPERATION.........................................................................603 PRESSURE LOADED TYPE GEAR PUMP.................................................................606 FIXED SIDE PLATE NPE GEAR PUMP.................................................................608 SA SERIES..........................................................................................609 STRUCTURE......................................................................................609 TESTING AND ADJUSTING..........................................................................613 DISASSEMBLY....................................................................................616 ASSEMBLY.......................................................................................620 MAINTENANCE STANDARD...........................................................................625 99 METRIC CONVERSIONS..................................................................................627
KOMATSU WHEEL LOADER WA320-1LC SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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