Komatsu Wheel Loader WA320-5H Shop Manual VEBM240100 PDF

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Komatsu Wheel Loader WA320-5H Shop Manual VEBM240100 – PDF DOWNLOAD

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Komatsu Wheel Loader WA320-5H Shop Manual VEBM240100 – PDF DOWNLOAD

Language : English
Pages :972
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Wheel Loader WA320-5H Shop Manual VEBM240100 – PDF DOWNLOAD

MACHINE MODEL
WA320-5H
SERIAL NUMBER
H50051 and up

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 Wheel Loader WA320-5H Shop Manual VEBM240100 – PDF DOWNLOAD

MACHINE MODEL
WA320-5H
SERIAL NUMBER
H50051 and up

SAFETY 3
SAFETY NOTICE 3
IMPORTANT SAFETY NOTICE 3
GENERAL PRECAUTIONS 3
PREPARATIONS FOR WORK 3
PRECAUTIONS DURING WORK 4
FOREWORD 5
GENERAL 5
STRUCTURE AND FUNCTION 5
TESTING AND ADJUSTING 5
DISASSEMBLY AND ASSEMBLY 5
MAINTENANCE STANDARD 5
OTHERS 5
HOW TO READ THE SHOP MANUAL 6
VOLUMES 6
DISTRIBUTION AND UPDATING 6
FILING METHOD 6
REVISED EDITION MARK 6
REVISIONS 6
SYMBOLS 6
HOISTING INSTRUCTIONS 7
HOISTING 7
WIRE ROPES 7
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 8
Disconnection 8
Connection 8
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 12
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH) 12
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS 12
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS 13
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS 13
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS 13
TIGHTENING TORQUE FOR 102 ENGINE SERIES 14
Tightening torque table for hoses (taper seal type and face seal type) 14
ELECTRIC WIRE CODE 15
CLASSIFICATION BY THICKNESS 15
CLASSIFICATION BY COLOR AND CODE 15
CONVERSION TABLE 16
METHOD OF USING THE CONVERSION TABLE 16
EXAMPLE 16
Millimeters to inches 16
Millimeters to Inches 17
Kilogram to Pound 17
Liter to US Gallon 18
Liter to UK Gallon 18
kgm to ft lb 19
kg/cm2 to lb/in2 20
Temperature 21
UNITS 22
Example: 22
01 GENERAL 23
GENERAL ASSEMBLY DRAWINGS 24
SPECIFICATIONS 25
WEIGHT TABLE 29
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS 31
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 33
Engine mount and transfer mount 34
Damper 35
Outline 35
Cooling system 36
Specification 36
Power train 37
Power train system diagram 38
Outline 39
Drive shaft (propeller shaft) 40
Outline 40
HST hydraulic piping diagram 41
HST pump 42
Specifications 42
Operation 43
Flow of power 43
Flow of oil 43
High-pressure relief valve 44
Function 44
Operation 45
Low-pressure relief valve 46
Function 46
Operation 46
HST charge pump 47
Outline 47
Specifications 47
Function 47
Speed-related valve (DA valve) 48
Function 48
Operation 48
High-pressure cut-off valve 49
Function 49
Operation 49
HST motor 50
HST motor 1 50
Specifications 50
HST motor 2 51
Specifications 51
Principle 52
Structure 52
Operation 52
EP servo valve 53
Function 53
Operation 53
HA servo valve 54
Function 54
Operation 54
Forward-reverse shuttle valve 55
Function 55
Operation 55
Transfer 56
Outline 56
Relationship between transfer clutch and transfer clutch pressure at each gear speed 56
Input shaft portion 58
Output shaft portion 60
Operation of clutch 64
When clutch is ON (fixed) 64
When clutch is OFF (released) 64
Low-speed mode 65
Operation 65
High-speed mode 66
Operation 66
Clutch solenoid valve 67
Operation 67
Axle 68
FRONT AXLE 68
REAR AXLE 69
Differential 70
FRONT DIFFERENTIAL 70
REAR DIFFERENTIAL 72
Outline 74
When traveling in a straight line 74
When turning 74
Torque proportioning differential 75
Outline 75
Operation 76
Straight travel (When the road resistances under both tires are the same) 76
Travel on soft ground (When the road resistances under both tires are different) 76
Limited-slip differential 78
FRONT 78
Operation of limited-slip differential 80
Brake torque generation mechanism of left and right side gears (5) 80
When traveling in a straight line 80
When turning 81
Final drive 82
Outline 83
Axle mounting and center hinge pin 84
Outline 85
Steering piping 89
Steering column 90
Priority valve 91
Outline 92
Operation 92
Orbit-roll valve 94
Outline 95
Structure 95
Operation 96
CONNECTION BETWEEN HAND PUMP AND SLEEVE100
Role of centering spring101
Cushion valve102
Outline102
Function102
Steering cylinder103
Emergency steering piping105
Emergency steering valve106
Operation107
When engine and steering pump are normal107
When engine or steering pump is abnormal108
Brake piping109
Brake valve110
Outline111
Operation111
When only either brake operates (When either brake fails)111
Inching valve114
Outline114
Charge valve116
Function117
Operation118
Accumulator (for brake)120
Function120
Slack adjuster121
Function122
Operation122
When brake is applied122
When brake is released122
Brake123
Outline124
Outline124
When brake is applied124
When brake is released124
Parking brake control125
Outline125
Parking brake126
Outline126
white 10-96128
Hydraulic piping130
Outline131
Work equipment lever linkage132
2-lever type132
Multi function mono-lever type133
(If equipped)133
Hydraulic tank134
Specifications134
Breather135
Prevention of negative pressure in tank135
Prevention of rise of pressure in tank135
4-gear pump unit136
SAR(3)90 + (2)32 + SBR(1)18 + 12136
Outline136
Accumulator (for PPC circuit)138
Outline138
Specifications138
Lock valve139
Outline139
E C S S valve140
(E C S S : Electronically Controlled Suspension System)140
(If equipped)140
Accumulator (forECSS)142
(If equipped)142
Function142
Specifications142
Hydraulic piping of cooling system143
Outline143
Cooling fan motor144
Specifications144
Function145
Principle of operation145
Work equipment control valve147
1 2-Spool valve147
2 3-spool valve151
3 Relief valve154
Function154
Operation154
4 Safety-suction valve155
Function155
Operation155
(1) Operation as safety valve155
(2) Operation as suction valve156
5 Suction valve156
Function156
Operation156
6 Cut-off valve158
Function160
Operating condition of cut-off valve160
(1) When work equipment pump pressure is lower than cut-off pressure160
(2) When work equipment pump pressure is higher than cut-off pressure161
7 Operation of work equipment control valve162
(1) Lift arm and bucket spool neutral position162
Operation162
(2) Lift arm spool raise position163
Operation163
(3) Lift arm spool lower position164
Operation164
(4) Lift arm spool float position165
Operation165
(5) Bucket spool dump position166
Operation166
(6) Bucket spool tilt position167
Operation167
Work equipment PPC valve168
2-lever type168
Operation170
Mono-lever type174
Operation176
Attachment PPC valve180
Operation182
Work equipment linkage184
Bucket186
Bucket positioner and boom kick-out188
Outline189
Bucket positioner189
Boom kick-out189
Operation of proximity switch190
When bucket is tilted190
Function of proximity switch191
When object of sensing is over sensing face of proximity switch191
When object of sensing is apart from over sensing face of proximity switch191
When lift arm is raised192
Function of proximity switch193
When object of sensing is over sensing face of proximity switch193
When object of sensing is apart from over sensing face of proximity switch193
Work equipment cylinder194
LIFT CYLINDER194
BUCKET CYLINDER194
Air conditioner195
AIR CONDITIONER PIPING195
Machine monitoring system196
Outline196
Individual circuit diagrams of the machine monitor198
Starting and lighting198
Power supply and network200
Speed meter specification200
Load meter specification200
Sensing202
HST safety control203
Autmatic preheating204
Load meter205
Load meter specification205
Machine monitor208
Speed meter specification208
Load meter specification (If equipped)209
List of items displayed on monitor210
Service mode functions214
Items Related to the Fault History of Electric System220
Items Related to the Fault History of Machine System223
Real-time monitor function Speed meter specification225
Real-time monitor function Load meter specification228
Real-time Monitoring Items231
(Reference) Inspection with real-time monitor234
Tuning function235
Maintenance functions237
How to input interval239
Setting required when optional device is installed241
Function of selecting optional device241
Speed meter specification241
Selection of tire deviation242
Function of selecting optional device244
Load meter specification244
Selection of tire deviation245
Selection of lift arm deviation245
Selection of printer setting state245
Machine serial No setting function247
Load Meter Function248
Input / Ouput signal257
Speed meter specification257
Load meter specification259
Electrical system (HST controller system)264
System diagram264
Control function265
HST controller268
Input and output signals268
Function of selecting directional selector switch269
(If equipped)269
Outline269
Function269
Operation270
When travel direction is changed with directional lever270
When directional selector switch is selected to be used270
When travel direction is changed with directional selector switch270
When directional lever has priority270
Engine start circuit271
Function271
Operation272
Engine stop circuit273
Operation273
Preheating circuit (automatic preheating system)274
Outline274
Operation274
Parking brake circuit275
Operation276
Electronically controlled suspension system278
Electronically Controlled Suspension System (Abbreviation: ECSS)278
(If equipped)278
Function278
System operation table278
Sensors279
Engine speed sensor279
Function279
Speed sensor279
Function279
ENGINE OIL PRESSURE SENSOR280
Function280
FUEL LEVEL SENSOR280
Function280
COOLANT TEMPERATURE SENSOR (FORMONITOR)281
HST oil temperature sensor281
Function281
COOLANT TEMPERATURE SENSOR (FOR PREHEATING)281
Function281
Axle oil temperature sensor282
Function282
HST oil pressure sensor Oil puressure sensor for load meter (Load meter specification)282
Function282
Steering oil pressure sensor283
(Machines equipped emergency steering)283
Emergency steering oil pressure sensor283
(Machines equipped emergency steering)283
Function283
HST filter clogging sensor283
Function283
COOLANT LEVEL SENSOR284
Function284
Engine oil level sensor285
Function285
Air cleaner clogging sensor285
Function285
Lift arm angle sensor (Load meter specification) (If equipped)286
Function286
STANDARD VALUE TABLE FOR engine288
STANDARD VALUE TABLE FOR CHASSIS289
20 TESTING AND ADJUSTING287
Tools for testing, adjusting, and troubleshooting294
Measuring engine speed296
Measuring exhaust gas color297
Adjusting valve clearance299
Measuring compression pressure300
Measuring blow-by pressure301
Testing and adjusting fuel injection timing302
Measuring engine oil pressure303
Measuring, testing operating force of accelerator pedal304
Adjusting engine stop solenoid306
Adjusting engine speed sensor307
Testing and adjusting air conditioner compressor belt tension307
Measuring directional lever308
Testing and adjusting HST oil pressure308
Measuring clutch control pressure313
Testing and adjusting steering wheel314
Testing and adjusting steering oil pressure315
Bleeding air from steering circuit316
Testing hydraulic fan317
Measuring brake pedal318
Testing and adjusting brake pedal linkage319
Measuring brake oil pressure322
Bleeding air from brake circuit325
Measuring parking brake performance326
Measuring and adjusting work equipment control lever328
Testing and adjusting work equipment hydraulic pressure329
Testing and adjusting work equipment PPC oil pressure330
Bleeding air332
Releasing remaining pressure in hydraulic circuit333
Testing and adjusting bucket positioner333
Testing and adjusting of boom kick-out335
Checking proximity switch actuation display lamp336
Special functions of machine monitor338
Pm CLINIC INSPECTION CHART371
TESTING AND ADJUSTING293
Points to remember when troubleshooting374
Sequence of events in troubleshooting375
Precautions when carrying out maintenance376
Check before troubleshooting384
Categories, procedure, and method of using troubleshooting charts385
Phenomena considered to be failures and troubleshooting no386
Connection table for connector pin numbers389
T-adapter table410
Connector types and mounting locat413
ions413
Connector layout drawing420
TROUBLESHOOTING373
Before troubleshooting code display426
Before troubleshooting electrical system428
Information contained in troubuleshooting table429
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)425
Before troubleshooting code display460
Before troubleshooting electrical system462
Information contained in troubuleshooting table463
TROUBLESHOOTING OF monitor SYSTEM (mon MODE)457
Before troubleshooting electrical system598
Information contained in troubuleshooting table599
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)597
Method of using troubleshooting chart680
Failure code and cause table682
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)679
Method of using troubleshooting charts704
TROUBLESHOOTING OF ENGINE (S MODE)703
How to read this manual728
Removal and installation of assemblies728
Disassembly and assembly of assemblies729
Precautions when carrying out operation730
Special tool list732
Sketch of special tools735
Removal, installation of fuel injection pump assembly740
Special tools740
Removal740
Installation742
Removal, installation of nozzle holder assembly744
Special tools744
Removal744
Installation745
Removal, installation of cylinder head assembly746
Special tools746
Removal746
Installation751
Removal, installation of engine assembly754
Removal754
Installation759
Removal, installation of radiator assembly761
Removal761
Installation761
Removal, installation of air aftercooler762
Removal762
Installation763
Removal, installation of hydraulic oil cooler assembly764
Removal764
Installation765
Removal, installation of cooling fan and fan motor assembly766
Removal766
Installation767
Removal, installation of fuel tank assembly768
Removal768
Installation769
Removal, installation of transfer770
Removal770
Installation771
Disassembly, assembly of transfer assembly772
Special tools772
Disassembly772
Assembly780
Removal, installation of parking brake assembly792
Removal792
Installation793
Disassembly, assembly of parking brake assembly794
Special tools794
Disassembly794
Assembly796
Removal, installation of front axle assembly799
Removal799
Installation800
Removal, installation of rear axle assembly801
Removal801
Installation803
Disassembly, assembly of axle housing assembly804
Special tools804
Disassembly804
Assembly809
Disassembly, assembly of differential assembly817
Special tools817
Assembly826
Removal, installation of HST pump and 4-gear pump assembly841
Removal841
Installation843
Removal, installation of HST motor 1 assembly844
Removal844
Installation845
Removal, installation of HST motor 2 assembly846
Removal846
Installation847
Removal, installation of work equipment control valve assembly848
Removal848
Installation849
Removal, installation of travel damper valve assembly850
Removal850
Installation851
Removal, installation of hydraulic tank assembly852
Removal852
Installation853
Removal, installation of work equipment assembly854
Removal854
Installation857
Disassembly and assembly of HST pump assembly861
Special tools list861
Disassembly861
Assembly870
Disassembly and assembly of HST motor assembly888
Special tools list888
Disassembly888
Assembly897
Disassembly, assembly of hydraulic cylinder assembly904
Special tools904
Disassembly904
Assembly907
Removal, installation of operator’s cab assembly911
Special tools911
Removal911
Installation915
Removal, installation of operator’s cab glass (Stuckglass)917
Special tools917
Removal917
Installation918
Coating materials924
Removal, installation of center hinge pin925
Special tools925
Removal925
Installation930
Removal, installation of counterweight936
Removal936
Installation937
Removal, installation of air conditioner unit assembly938
Special tools938
Removal938
Installation940
Removal, installation of air conditioner compressor assembly941
Special tools941
Removal941
Installation941
Removal, installation of monitor panel942
Removal942
Installation945
30 DISASSEMBLY AND ASSEMBLY727
90 OTHERS947

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S.M 26/12/24