Komatsu Wheel Loader GALEO WA320-L, Parallel Tool Carrier WA320PT-L Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader GALEO WA320-5L, Parallel Tool Carrier WA320PT-5L, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loader GALEO WA320-5L, Parallel Tool Carrier WA320PT-5L workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEAM013800 - Parallel Tool Carrier GALEO WA320PT-5L Operation & Maintenance Manual.pdf
CEBM012004 - Wheel Loader GALEO WA320-5L Shop Manual.pdf
CEBM013602 - Parallel Tool Carrier WA320PT-5L Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 2,432 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEAM013800 - Parallel Tool Carrier GALEO WA320PT-5L Operation & Maintenance Manual....1
COVER....1
INTRODUCTION....7
FOREWORD....8
SAFETY INFORMATION....10
APPROVED AND NON-APPROVED USES....11
NON-APPROVED....11
PRODUCT IDENTIFICATION....12
MACHINE SERIAL NUMBER....12
ENGINE SERIAL NUMBER AND EMISSION LABEL....13
SERVICE METER LOCATION....13
SERIAL NUMBERS AND DEALER INFORMATION....14
CONTENTS....15
SAFETY....25
GENERAL SAFETY RULES AND PRECAUTIONS....26
GENERAL SAFETY RULES....26
SAFETY FEATURES....27
PERSONAL PROTECTIVE EQUIPMENT....27
UNAUTHORIZED MODIFICATIONS....28
LEAVING OPERATOR’S COMPARTMENT....28
MOUNTING AND DISMOUNTING....29
FIRE PREVENTION FOR FUEL AND OIL....30
DUST HAZARD PRECAUTIONS....30
CRUSH OR PINCH POINT DANGERS....30
FIRE EXTINGUISHER AND FIRST AID KIT....31
INSIDE OPERATOR’S COMPARTMENT....31
PRECAUTIONS WHEN USING ROPS....31
PRECAUTIONS FOR ATTACHMENTS....31
STARTING YOUR WORK OPERATIONS....32
WORK SITE HAZARDS....32
AVOIDING DANGEROUS SITUATIONS....32
WORKING CLEARANCES....34
RULES FOR ROAD TRAVEL....35
TRAVELING IN REVERSE....35
TRAVELING ON ICY OR SNOW-COVERED SURFACES....35
WORKING ON LOOSE OR UNSTABLE GROUND....35
TRAVEL ON SLOPES....36
PARKING THE MACHINE....37
PRECAUTIONS DURING MAINTEMANCE OPERATIONS....38
WARNING TAGS....38
EQUIPMENT STORAGE....38
WORKING UNDER THE MACHINE....39
USING DROP LAMPS....39
KEEPING THE MACHINE CLEAN....40
RUNNING THE MACHINE DURING MAINTENANCE....40
RULES FOR REFUELING THE MACHINE....41
COOLING SYSTEM PRECAUTIONS....41
BATTERY PRECAUTIONS....42
STARTING THE MACHINE....42
HIGH PRESSURE HOSES....43
HIGH TEMPERATURES AREAS....43
DISPOSAL OF WASTE MATERIALS....43
INFLATING TIRES....44
ACCUMULATOR....44
CRITICAL PARTS....44
VIBRATIONS TO WHICH THE OPERATOR IS EXPOSED....44
SAFETY AND WARNING DECALS....45
LOCATION OF THE SAFETY DECALS....45
OPERATION....53
GENERAL VIEW OF MACHINE....54
OUTSIDE VIEW OF THE MACHINE....54
INSIDE VIEW OF THE CAB....55
DESCRIPTION OF ALERTS, GAUGES AND MONITOR SYSTEM....56
INSTRUMENT BEZEL....56
CENTRAL WARNING LAMP....57
CENTRAL WARNING LAMP....57
EMERGENCY STOP WARNING SYSTEM....58
BRAKE PRESSURE WARNING LAMP....58
ENGINE OIL PRESSURE WARNING LAMP....58
BATTERY CHARGE WARNING LAMP....59
STEERING OIL PRESSURE WARNING LAMP....59
CAUTION LAMPS....60
AXLE OIL TEMPERATURE CAUTION LAMP....60
PARKING BRAKE REMINDER LAMP....61
HST OIL TEMPERATURE CAUTION LAMP....61
COOLANT TEMPERATURE CAUTION LAMP....61
FUEL LEVEL CAUTION LAMP....61
INSPECTION AND MAINTENANCE ALLERTS....62
RADIATOR COOLANT LEVEL ALERT LAMP....62
ENGINE OIL LEVEL ALERT LAMP....63
MAINTENANCE ALERT LAMP....63
HST OIL FILTER CLOG ALERT LAMP....63
AIR CLEANER CLOGGING ALERT LAMP....63
MODE ALERT LAMPS....64
PARKING BRAKE INDICATOR LAMP....64
ENGINE PREHEAT LAMP....64
STEERING OIL PRESSURE LAMP (GREEN)....65
DIRECTION INDICATOR LAMP....65
DIRECTION INDICATOR LAMP....65
TURN SIGNAL INDICATOR LAMP....65
HEAD LAMP BEAM INDICATOR....65
GAUGE DISPLAY....66
HST OIL TEMPERATURE GAUGE....66
ENGINE COOLANT TEMPERATURE GAUGE....67
FUEL LEVEL GAUGE....67
SPEEDOMETER....67
METER MODE DISPLAY....67
MACHINE ELECTRONIC MONITORING DISPLAY....68
MONITOR MODE SELECTOR SWITCHES....68
MODE SELECTOR SWITCH 1....68
MODE SELECTOR SWITCH 2....69
MONITOR DISPLAY INFORMATION....69
HOUR METER AND ODOMETER DISPLAY....69
ADJUSTING MONITOR BRIGHTNESS....69
PROGRAMING TELEPHONE NUMBER....69
ACTION CODE DISPLAY....70
FAILURE CODE DISPLAY....71
SERVICE DISPLAY....71
SELECTING LANGUAGE....73
SETTING HST FUNCTION....73
MACHINE SWITCHES AND CONTROLS....74
SWITCHES....75
IGNITION SWITCH....75
SPEED RANGE SELECTOR SWITCH....75
VARIABLE SHIFT CONTROL SWITCH....75
TRACTION CONTROL SWITCH....76
ECSS SWITCH....76
HEAD LAMPS-TURN SIGNALS-DIMMER SWITCH....77
HORN BUTTON....77
HAZARD LAMP SWITCH....78
FRONT WORK LAMPS SWITCH....78
REAR WORK LAMPS SWITCH....78
MODE SELECTOR SWITCH 1....78
MODE SELECTOR SWITCH 2....79
ATTACHMENT SELECT SWITCH....79
DUMP SPEED SWITCH....79
QUICK COUPLER SWITCH....79
FRONT WIPER SWITCH....79
REAR WIPER SWITCH....80
CIGARETTE LIGHTER....80
CAB LAMP SWITCH....80
REAR WINDOW HEATER SWITCH....80
CONTROLS....81
DIRECTIONAL CONTROL LEVER....81
WORK EQUIPMENT LOCK LEVER....81
LIFT ARM CONTROL LEVER....81
BUCKET CONTROL LEVER....82
AUXILIARY CONTROL LEVER....82
BRAKE PEDALS....83
ACCELERATOR PEDAL....83
PARKING BRAKE LEVER....83
STEERING TILT LOCK LEVER....84
SECURITY, LOCKS AND SAFETY FEATURES....85
IGNITION KEY LOCKED AREAS....85
CAB DOOR LOCKS....85
ENGINE ACCESS DOORS....85
REAR GRIL AND FUEL CAP....86
PADLOCKED AREAS....87
BATTERY AND TOOL BOX....87
TRANSFER CASE....87
UPPER HOOD ACCESS PANEL....87
CAB DOORS AND WINDOWS....88
CAB DOOR LOCK BUTTON....88
CAB DOOR OPEN LOCK....88
CAB WINDOW LOCK CANCEL KNOB....88
SAFETY LOCK BAR....89
FUSES AND ELECTRICAL OUTLETS....90
FUSE PANEL....90
FUSE BOX (A)....90
FUSE BOX (B)....91
SLOW BLOW FUSE....91
ADDITIONAL FEATURES....92
POWER OUTLET....92
COOL BOX....92
STORAGE BOX....92
AIR CONDITIONING SYSTEM....93
BLOWER MOTOR SWITCH....93
AIR CONDITIONER SWITCH....93
MODE SELECTOR SWITCH....94
(FRESH/RECIRC) SELECTOR SWITCH....94
TEMPERATURE CONTROL SWITCH....94
CLIMATE CONTROL OPERATION....95
WHEN NOT USING THE AIR CONDITIONER....95
AM/FM RADIO-CASSETTE STEREO....96
RADIO OPERATION....97
POWER SWITCH/VOLUME....97
AUTO-STORE/PRESET SCAN BUTTON....97
BASS CONTROL KNOB....97
TREBLE CONTROL KNOB....97
LOUDNESS BUTTON....98
TIME/RADIO DISPLAY SELECTOR BUTTON....98
TAPE EJECT BUTTON....98
CASSETTE DOOR....98
FAST FORWARD, REWIND BUTTONS....99
PRESET BUTTONS....99
METAL TAPE BUTTON....99
SEEK TUNING BUTTONS....99
BAND SELECTOR BUTTON....100
USING RADIO FEATURE....100
USING AUTO PRESET....100
USING MANUAL PRESET....100
LISTENING TO RADIO....101
LISTENING TO CASSETTE TAPE....101
REVERSING TAPE....101
START-UP PREPERATIONS AND CHECKS....102
PRE-OPERATIONAL CHECKS....102
PERFORM A WALK AROUND CHECK OF YOUR MACHINE....102
TIRE PRESSURES AND CHECKS....103
CHECKS UNDER THE HOOD....104
IN THE OPERATOR’S CAB....106
START-UP AND CHECKS....109
STARTING YOUR WORK OPERATIONS....111
WARMING THE HYDRAULIC OIL....111
PARALLEL TOOL KIT....112
WORK EQUIPMENT CONTROL LEVERS....112
USING THE FORKS....113
FORK LIFT LIMITATIONS....113
LOAD HANDLING SAFETY TIPS....114
TRAVELING SAFETY TIPS....114
LOADING OPERATIONS....114
TRANSPORTING A LOAD....116
UNLOADING....116
ADJUSTING THE WORK EQUIPMENT....118
ADJUSTING THE BOOM KICKOUT....118
ADJUSTING THE BUCKET POSITIONER....118
BUCKET LEVEL INDICATOR....119
ADJUSTING FORK POSITIONER....119
USING THE HYDRAULIC QUICK COUPLER....121
REMOVING THE ATTACHMENT....121
INSTALLING THE ATTACHMENT....122
TRAVELING, STOPPING AND PARKING THE MACHINE....125
TRAVELING....125
CHANGING DIRECTION....127
TURNING THE MACHINE....127
TURNING ON SLOPES....127
EMERGENCY STEERING (IF EQUIPPED)....128
STOPPING THE MACHINE....129
PARKING THE MACHINE....130
TRANSPORTING THE MACHINE....132
LOADING AND SECURING THE MACHINE....132
LIFTING THE MACHINE....133
LIFTING LOCATIONS AND PROCEDURES....133
USING WIRE ROPE....134
PRE LIFTING PROCEDURES....134
TOWING THE MACHINE....136
COLD WEATHER OPERATION....137
FUEL AND LUBRICANTS....137
COOLANT....137
PRECAUTIONS AFTER COMPLETION OF WORK....137
AFTER COLD WEATHER....137
WARMING UP THE STEERING....137
LONG-TERM STORAGE....138
BEFORE STORAGE....138
DURING STORAGE....138
AFTER STORAGE....138
MAINTENANCE....139
BASIC TROUBLESHOOTING....140
ENGINE....140
CHASSIS....141
ELECTRICAL....142
GUIDE TO MAINTENANCE....143
CARRYING OUT KOWA (KOMATSU OIL WEAR ANALYSIS)....144
KOWA ANALYSIS ITEMS....144
OIL SAMPLING....144
WEAR PARTS....145
FUEL SPECIFICATIONS....146
FUELS....146
NOTES REGARDING THE ELECTRICAL SYSTEM....147
NOTES REGARDING LUBRICATION....147
PROPER SELECTION ACCORDING TO THE AMBIENT TEMPERATURE....148
STANDARD TIGHTNING TORQUES....149
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....150
MAINTENANCE SCHEDULE CHART....151
SERVICING WHEN REQUIRED....151
EVERY 50 HOURS SERVICE....151
EVERY 100 HOURS SERVICE....151
EVERY 250 HOURS SERVICE....151
EVERY 500 HOURS SERVICE....151
EVERY 1000 HOURS SERVICE....152
EVERY 2000 HOURS SERVICE....152
EVERY 4000 HOURS SERVICE....152
FIRST 250 HOURS SERVICE....152
SERVICING WHEN REQUIRED....153
CHECK, CLEAN OR REPLACE AIR CLEANER ELEMENT....153
CHECK....153
CLEAN....153
REPLACE AIR CLEANER ELEMENT....154
FLUSHING THE COOLING SYSTEM....156
CHECKING OIL LEVEL IN TRANSFER CASE, ADD OIL....158
CHECKING AXLE OIL LEVEL, ADD OIL....159
CLEANING AXLE CASE BREATHER....160
CLEANING AIR CONDITIONER CONDENSER....160
WASHING METHOD....160
CHECKING WINDOW WASHER FLUID LEVEL....161
CLEANING RADIATOR COOLING FINS....161
CLEANING TRANSFER OIL COOLER FINS....162
CHECKING ELECTRICAL INTAKE AIR HEATER....162
REPLACING BOLT ON CUTTING EDGE....162
REPLACING BUCKET TEETH....163
CHECKING AIR CONDITIONER....163
REPLACING SLOW BLOW FUSE....164
SELECTION AND INSPECTION OF TIRES....165
SELECTION OF TIRES....165
INFLATION OF TIRES....165
EVERY 50 HOURS SERVICE....166
DRAIN WATER, SEDIMENT FROM FUEL TANK....166
EVERY 100 HOURS SERVICE....167
LUBRICATING REAR AXLE PIVOT PIN....167
CLEANING FRESH AIR FILTER....167
CHECKING OIL LEVEL IN HYDRAULIC TANK, ADD OIL....168
EVERY 250 HOURS SERVICE....169
CHECK BATTERY ELECTROLYTE LEVEL....169
CHECKING ELECTROLYTE LEVEL FROM SIDE OF BATTERY....169
WHEN ELECTROLYTE LEVEL CANNOT BE CHECKED FROM THE BATTERY SIDE....170
CHECKING PARKING BRAKE....171
CHECKING V-BELT TENSION/ADJUST....171
INSPECTION....171
CHECK WHEN CHANGING THE V-BELT....171
ADJUSTING....171
CHECKING FOR LOOSE WHEEL HUB BOLTS, TIGHTENING....172
CLEANING A/C RECIRCULATION FILTER....172
LUBRICATING WORK EQUIPMENT....173
EVERY 500 HOURS SERVICE....175
CHANGING ENGINE OIL AND OIL FILTER CARTRIDGE....175
REPLACING ENGINE OIL FILTER CARTRIDGE....176
CLEANING WATER SEPARATOR STRAINER....177
EVERY 1000 HOURS SERVICE....178
CHANGING OIL IN TRANSFER CASE....178
CLEANING TRANSFER CASE BREATHER....179
REPLACING HST OIL FILTER ELEMENT....180
LUBRICATING CHASSIS....180
CHECKING PARTS OF TURBOCHARGER....181
CHECKING PLAY IN TURBOCHARGER ROTOR....181
CHECKING ALTERNATOR BELT TENSION, REPLACE....181
EVERY 2000 HOURS SERVICE....182
CHANGING HYDRAULIC OIL AND FILTER ELEMENT....182
REPLACING HYDRAULIC TANK BREATHER ELEMENT....183
CHANGING AXLE OIl....183
REPLACING AIR CONDITIONER RECIRCULATION AIR FILTER....184
CHECKING ALTERNATOR, STARTING MOTOR....184
CHECKING ENGINE VALVE CLEARANCE, ADJUST....184
CHECKING BRAKE DISC WEAR....184
CLEANING AND CHECK TURBOCHARGER....185
CHECKING ACCUMULATOR GAS PRESSURE....185
CHECKING VIBRATION DAMPER....185
CHECKING FUNCTION OF ACCUMULATOR....185
PPC ACCUMULATOR....185
EVERY 4000 HOURS SERVICE....186
LUBRICATING DRIVE LINE....186
CHECK WATER PUMP....186
ADDITIONAL SERVICE TIPS....187
HANDLING CAB WIPER....187
PREVENTING DAMAGE TO WIPER ARM BRACKET....187
ENGINE STARTING PROBLEMS....187
WHEN ENGINE CAN BE USED....187
WHEN ENGINE CANNOT BE USED....187
BATTERY SERVICING....188
IF BATTERY IS DISCHARGED....188
PRECAUTIONS....188
REMOVAL AND INSTALLATION OF BATTERY....188
PRECAUTIONS WHEN CHARGING THE BATTERY....189
STARTING ENGINE WITH BOOSTER CABLES....189
PRECAUTIONS WHEN USING BOOSTER CABLES....189
CONNECTING THE BOOSTER CABLES AND STARTING THE ENGINE....190
STARTING THE ENGINE....190
DISCONNECTING THE BOOSTER CABLES....190
SPECIFICATIONS....191
TECHNICAL DATA....192
OVERALL DIMENSIONS WITH WORK EQUIPMENT ATTACHED....192
FORK LIFT KIT....192
MATERIAL HANDLING ARM....193
LOADER BUCKET....194
BASIC MACHINE SPECIFICATIONS....195
WEIGHT CHANGES....195
ENGINE....195
TRANSMISSION....195
AXLES AND FINAL DRIVES....196
BRAKES....196
STEERING SYSTEM....196
SERVICE REFILL CAPACITIES....196
RECOMMENDED LUBRICANTS....197
OPTIONAL ATTACHMENTS....199
AUTHORIZED OPTIONAL EQUIPMENT....200
BASIC PRECAUTIONS....200
SELECTING BUCKET AND TIRES....200
USING LOADER WORK EQUIPMENT....201
LOADING PILED SOIL OR BLASTED ROCK....201
LOAD AND CARRY OPERATIONS....203
LOADING TRUCKS OR HOPPERS....203
V-SHAPED LOADING TECHNIQUE....203
CUTTING OR DIGGING....204
GRADING OR LEVELING A SURFACE....205
USING MULTI-FUNCTION LEVER....206
EXPLANATION OF OPERATION....206
WORK EQUIPMENT LEVER....206
DIRECTIONAL SELECTOR SWITCH....207
DIRECTIONAL SELECTOR ACTUATION SWITCH....207
DIRECTIONAL SELECTOR LAMP....208
USING SWITCH TO CHANGE BETWEEN FORWARD AND REVERSE....208
OPTIONAL WORK EQUIPMENT....210
COUPLER SYSTEM....210
ATTACHMENTS....210
CEBM012004 - Wheel Loader GALEO WA320-5L Shop Manual....213
COVER....213
CONTENTS....214
FOREWORD....225
SAFETY....225
SAFETY NOTICE....225
IMPORTANT SAFETY NOTICE....225
GENERAL PRECAUTIONS....225
PREPARATIONS FOR WORK....225
PRECAUTIONS DURING WORK....225
GENERAL....227
HOW TO READ THE SHOP MANUAL....228
VOLUMES....228
DISTRIBUTION AND UPDATING....228
FILING METHOD....228
REVISED EDITION MARK....228
REVISIONS....228
SYMBOLS....228
HOISTING INSTRUCTIONS....229
HOISTING....229
WIRE ROPES....229
PUSH-PULL TYPE COUPLER....230
COATING MATERIALS....232
STANDARD TIGHTENING TORQUE....234
BOLTS AND NUTS STANDARD TIGHTENING TORQUE....234
HOSE NUTS TIGHTENING TORQUE....235
SPLIT FLANGE BOLTS TIGHTENING TORQUE....235
FLARED NUTS TIGHTENING TORQUE....235
O-RING BOSS PIPING JOINTS TIGHTENING TORQUE....236
O-RING BOSS PLUGS TIGHTENING TORQUE....236
102 ENGINE SERIES TIGHTENING TORQUE....237
HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE) TIGHTENING TORQUE....238
ELECTRIC WIRE CODE....239
CLASSIFICATION BY THICKNESS....239
CLASSIFICATION BY COLOR AND CODE....239
CONVERSION TABLES....240
METHOD OF USING THE CONVERSION TABLE....240
UNITS....246
01 GENERAL....247
GENERAL ASSEMBLY DRAWINGS....248
SPECIFICATIONS....249
WEIGHT TABLE....253
LIST OF LUBRICANTS AND COOLANT....254
10 STRUCTURE AND FUNCTION....257
ENGINE AND DRIVE SYSTEM MOUNTING....263
DRIVE DAMPER ASSEMBLY....264
DRIVE DAMPER OPERATION....264
COOLING SYSTEM ASSEMBLY....265
REVERSING FAN SYSTEM....266
REVERSING FAN MANIFOLD....267
PROPORTIONAL RELIEF VALVE....268
2-POSITION, 4-WAY SPOOL VALVE....269
FAN CONTROLLER....270
POWER TRAIN....271
POWER TRAIN SYSTEM....272
POWER TRAIN OPERATION....273
FRONT AND REAR DRIVE LINES....274
DRIVE LINE OPERATION....274
HST HYDRAULIC PIPING DIAGRAM....275
HST PUMP....276
HST PUMP OPERATION....277
POWER FLOW....277
OIL FLOW....278
PRESSURE RELIEF VALVES....279
HIGH PRESSURE....279
FUNCTION....279
VALVE OPERATION....280
LOW PRESSURE....281
VALVE OPERATION....281
HST CHARGE PUMP....282
PUMP OPERATION....283
FUNCTION....283
SPEED RELATED VALVE (DA VALVE)....284
FUNCTION....284
DA VALVE OPERATION....284
HIGH-PRESSURE CUT-OFF VALVE....285
FUNCTION....285
CUT-OFF VALVE OPERATION....285
HST MOTORS....286
HST MOTOR 1....286
HST MOTOR 2....287
HST OPERATING PRINCIPLE....288
STRUCTURE....288
MOTOR OPERATION....288
EP SERVO VALVE....289
FUNCTION....289
VALVE OPERATION....289
HA SERVO VALVE....290
FUNCTION....290
VALVE OPERATION....290
FORWARD-REVERSE SHUTTLE VALVE....291
FUNCTION....291
SHUTTLE VALVE OPERATION....291
TRANSFER SYSTEM....292
INTERNAL VIEW OF TRANSFER....293
INPUT SHAFT SPECIFICATIONS....294
OUTPUT SHAFT SPECIFICATIONS....296
SPECIFICATIONS....298
CLUTCH OPERATION....298
WHEN “ON”....298
WHEN “OFF”....298
LOW SPEED MODE....299
MODE OPERATION....299
HIGH SPEED MODE....300
MODE OPERATION....300
CLUTCH SOLENOID VALVE....301
SOLENOID VALVE OPERATION....301
AXLES....302
FRONT AXLE....302
REAR AXLE....303
STANDARD DIFFERENTIALS....304
FRONT DIFFERENTIAL....304
SPECIFICATIONS....305
REAR DIFFERENTIAL....306
SPECIFICATIONS....307
DIFFERENTIAL FUNCTION....308
DIFFERENTIAL OPERATION....308
TORQUE PROPORTIONING....309
DIFFERENTIAL OPERATION....309
LIMITED-SLIP DIFFERENTIAL....310
FRONT DIFFERENTIAL....310
SPECIFICATIONS....311
LIMITED-SLIP OPERATION....311
FINAL DRIVE....314
SPECIFICATIONS....314
FINAL DRIVE OUTLINE....315
AXLE MOUNTING AND CENTER HINGE PIN....316
AXLE MOUNTING....316
AXLE MOUNTING OUTLINE....317
CENTER HINGE PIN ASSEMBLY....318
SPECIFICATIONS....319
SPECIFICATIONS....320
STEERING PIPING....321
STEERING COLUMN....322
PRIORITY VALVE....323
PRIORITY VALVE OUTLINE....324
ORBIT-ROLL VALVE....326
ORBITAL-ROLL VALVE OPERATION....327
STRUCTURE....327
STEERING WHEEL IN NEUTRAL POSITION....328
STEERING WHEEL TURNING LEFT....329
STEERING WHEEL STOPPED....330
CONNECTION BETWEEN HAND PUMP AND SLEEVE....331
ROLE OF CENTERING SPRING....332
CUSHION VALVE....333
CUSHION VALVE OPERATION....333
FUNCTION....333
CYLINDER LAY-OUT AND STEERING CYLINDER....334
STEERING CYLINDER....335
EMERGENCY STEERING PIPING....336
EMERGENCY STEERING VALVE....337
STEERING SYSTEM DURING NORMAL OPERATION....338
STEERING SYSTEM WHEN FAILURE OCCURS....339
BRAKE PIPING....340
BRAKE VALVE ASSEMBLY....341
VALVE ASSEMBLY OUTLINE....342
WHEN BRAKE PEDAL IS PRESSED....342
WHEN BRAKE IS BALANCED....343
WHEN BRAKE IS RELEASED....344
INCHING VALVE FUNCTION....345
INCHING VALVE OUTLINE....345
CHARGE VALVE ASSEMBLY....346
FUNCTION OF CHARGE VALVE....348
VALVE OPERATION....348
ACCUMULATOR (BRAKE SYSTEM)....350
ACCUMULATOR FUNCTION....350
SLACK ADJUSTER....351
SLACK ADJUSTER FUNCTION....352
BRAKE....353
BRAKE OUTLINE....354
PARKING BRAKE CONTROL....355
BRAKE SYSTEM OUTLINE....355
PARKING BRAKE UNIT....356
PARKING BRAKE OUTLINE....356
HYDRAULIC PIPING....357
PIPING OUTLINE....358
WORK EQUIPMENT CONTROL LINKAGE....359
MULTI FUNCTION MONO LEVER....360
HYDRAULIC TANK....361
SYSTEM SPECIFICATIONS....362
BREATHER....362
4-GEAR PUMP UNIT....363
PUMP OUTLINE....363
ACCUMULATOR (PPC CIRCUIT)....365
ACCUMULATOR OUTLINE....365
SPECIFICATIONS....365
LOCK VALVE....366
LOCK VALVE OUTLINE....366
TRAVEL DAMPER VALVE....367
ACCUMULATOR (TRAVEL DAMPER)....369
ACCUMULATOR FUNCTION....369
SPECIFICATIONS....369
HYDRAULIC PIPING FOR COOLING SYSTEM....370
PIPING OUTLINE....370
COOLING FAN MOTOR....371
FAN MOTOR SPECIFICATIONS....372
MOTOR FUNCTION....372
PRINCIPLE OF OPERATION....372
WORK EQUIPMENT CONTROL VALVE....374
2-SPOOL VALVE....374
3-SPOOL VALVE....377
3-RELIEF VALVE....380
VALVE FUNCTION....380
VALVE OPERATION....380
4-RELIEF VALVE....381
VALVE FUNCTION....381
VALVE OPERATION....381
SUCTION VALVE....382
VALVE FUNCTION....382
VALVE OPERATION....382
CUT-OFF VALVE....383
VALVE FUNCTION....384
WORK EQUIPMENT CONTROL VALVE OPERATION....386
WORK EQUIPMENT PPC VALVE....392
2-LEVER TYPE....392
PPC VALVE OPERATION....394
WHEN BUCKET IS IN NEUTRAL....394
FINE CONTROL MODE (NEUTRAL ¤ FINE)....395
(FINE ¤ NEUTRAL)....395
LEVER IS MOVED TO END OF STRTOKE....396
LEVER IS IN “FLOAT”....396
MONO-LEVER TYPE....397
MONO-LEVER OPERATION....399
IN NEUTRAL POSITION....399
FINE CONTROL MODE (NEUTRAL ¤ FINE)....400
(FINE ¤ NEUTRAL)....400
LEVER IS MOVED TO END OF STROKE....401
LEVER IS IN “FLOAT”....401
ATTACHMENT PPC VALVE....402
PPC VALVE OPERATION....403
IN NEUTRAL POSITION....403
AT FULL STROKE....405
WORK EQUIPMENT LINKAGE....406
BUCKET....408
BUCKET POSITIONER AND BOOM KICK-OUT....409
POSITIONER SYSTEM OUTLINE....410
BUCKET POSITIONER....410
BOOM KICK-OUT....410
PROXIMITY SWITCH OPERATION....410
FUNCTION OF PROXIMITY SWITCH....413
FUNCTION OF PROXIMITY SWITCH....416
WORK EQUIPMENT CYLINDER....417
LIFT CYLINDER....417
BUCKET CYLINDER....417
AIR CONDITIONER SYSTEM....418
AIR CONDITIONER PIPING....418
MACHINE MONITORING SYSTEM....419
SYSTEM OUTLINE AND CIRCUIT DIAGRAMS....419
MACHINE MONITOR (Starting And Lighting)....421
POWER SUPPLY NETWORK....422
MACHINE MONITOR (STANDARD)....429
MACHINE MONITOR (OPTIONAL LOAD METER)....430
ITEMS DISPLAYED ON MONITOR....431
MONITOR MODE FUNCTIONS....436
ELECTRICAL SYSTEM FAILURE HISTORY....436
MACHINE SYSTEM FAILURE HISTORY....436
REAL-TIME MONITOR....437
SPEED METER SPECIFICATIONS....439
ITEMS RELATED TO THE FAULT HISTORY OF ELECTRICAL SYSTEM....441
ITEMS RELATED TO THE FAULT HISTORY OF MACHINE SYSTEM....444
REAL-TIME MONITOR FUNCTION....446
SPEED METER SPECIFICATION....446
LOAD METER SPECIFICATION....449
TUNING FUNCTION....456
LOAD METER SPECIFICATIONS....456
MAINTENANCE FUNCTION....458
HOW TO INPUT INTERVAL....460
FUNCTION OF SELECTING OPTIONAL DEVICE....462
SPEED METER....462
SELECTION OF TIRE....463
LOAD METER....464
SETTING MACHINE SERIAL NUMBER....466
LOAD METER FUNCTION....467
INPUT/OUTPUT SIGNAL....475
SPEED METER SPECIFICATIONS....475
LOAD METER SPECIFICATIONS....477
ELECTRICAL SYSTEM (HST CONTROLLER)....482
CONTROL FUNCTION....483
HST CONTROLLER....486
FORWARD-REVERSE SELECTOR SWITCH (IF EQUIPPED)....488
SYSTEM OUTLINE....488
FUNCTION....488
ENGINE START CIRCUIT....490
CIRCUIT OPERATION....490
FUNCTION....491
ENGINE STOP CIRCUIT....492
CIRCUIT OPERATION....492
AUTOMATIC PREHEAT SYSTEM CIRCUIT....493
SYSTEM OUTLINE....493
PREHEAT OPERATION....493
PARKING BRAKE CIRCUIT....494
PARKING BRAKE OPERATION....495
ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM....497
SYSTEM FUNCTION....497
SENSORS....498
ENGINE SPEED SENSOR....498
SYSTEM FUNCTION....498
TRAVEL SPEED SENSOR....498
SYSTEM FUNCTION....498
ENGINE OIL PRESSURE SENSOR....499
SYSTEM FUNCTION....499
FUEL LEVEL SENSOR....499
SYSTEM FUNCTION....499
ENGINE COOLANT AND HST OIL TEMPERATURE SENSOR....500
SYSTEM FUNCTION....500
PREHEATING COOLANT TEMPERATURE SENSOR....500
SYSTEM FUNCTION....500
AXLE OIL TEMPERATURE SENSOR....501
SYSTEM FUNCTION....501
HST OIL PRESSURE SENSOR (LOAD METER)....501
SYSTEM FUNCTION....501
EMERGENCY STEERING OIL PRESSURE SENSOR (IF EQUIPPED)....502
SYSTEM FUNCTION....502
HST FILTER CLOG SENSOR....502
SYSTEM FUNCTION....502
COOLANT LEVEL SENSOR....503
SYSTEM FUNCTION....503
ENGINE OIL LEVEL SENSOR....504
SYSTEM FUNCTION....504
AIR CLEANER CLOG SENSOR....504
SYSTEM FUNCTION....504
LIFT ARM ANGLE SENSOR (IF EQUIPPED)....505
SYSTEM FUNCTION....505
20 TESTING, ADJUSTING AND TROUBLESHOOTING....507
STANDARD VALUE TABLE....509
ENGINE....509
CHASSIS....510
SPECIAL TOOLS....515
ENGINE COMPONENTS....518
MEASURING EXHAUST SMOKE....518
MEASURING EXHAUST TEMPERATURE....518
ADJUSTING VALVE CLEARANCE....518
MEASURING COMPRESSION PRESSURE....518
MEASURING CRANCASE PRESSURE....518
MEASURING ENGINE OIL PRESSURE....518
MEASURING BOOST PRESSURE....518
MEASURING FUEL PRESSURE....518
ADJUSTING ENGINE SPEED SENSOR....518
BLEEDING AIR FROM FUEL SYSTEM....518
MEASURING ENGINE SPEED....519
MEASURING LOW AND HIGH IDLE....519
MEASURING HST STALL SPEED....520
MEASURING HYDRAULIC STALL....520
MEASURING FULL STALL SPEED....520
ACCELERATOR PEDAL....521
TESTING PEDAL FORCE....521
OPERATING ANGLE OF PEDAL....522
ADJUSTING ENGINE STOP SOLENOID....523
ADJUSTING ENGINE SPEED SENSOR....524
REFRIGERENT COMPRESSOR BELT....525
DIRECTIONAL LEVER....526
HST OIL PRESSURE....527
MEASURING....527
ADJUSTING....530
CLUTCH CONTROL PRESSURE....532
STEERING WHEEL....533
MEASURING STEERING WHEEL END PLAY....533
MEASURING OPERATING FORCE ON STEERING WHEEL....533
MEASURING OPERATING TIME FOR STEERING WHEEL....534
STEERING OIL PRESSURE....535
MEASURING MAIN RELIEF PRESSURE....535
ADJUSTING MAIN RELIEF PRESSURE....535
BLEEDING AIR FROM STEERING CIRCUIT....536
HYDRAULIC FAN....537
MEASURING FAN SPEED....537
MEASURING OIL PRESSURE....537
REVERSING FAN CONTROLLER, IF EQUIPPED....538
LED INDICATORS....538
MEASURING BRAKE PEDAL....539
BRAKE PEDAL LINKAGE....540
MEASURING BRAKE PERFORMANCE....541
ACCUMULATOR CHARGE PRESSURE....542
BRAKE OIL PRESSURE....543
MEASURING WEAR OF BRAKE DISC....545
BLEEDING AIR FROM BRAKE CIRCUIT....546
PARKING BRAKE PERFORMANCE....547
PARKING BRAKE LINKAGE....548
WORK EQUIPMENT CONTROL LEVER....550
WORK EQUIPMENT PRESSURE....551
WORK EQUIPMENT PPC OIL PRESSURE....553
TESTING AND ADJUSTING....553
BLEEDING AIR....555
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....556
BUCKET POSITIONER....557
BOOM KICK-OUT....558
PROXIMITY SWITCH ACTUATION DISPLAY LAMP....559
PROCEDURE FOR CHECKING DIODE....561
SPECIAL FUNCTIONS OF MACHINE MONITOR....562
FLOW OF MODES AND FUNCTIONS....563
REAL-TIME MONITORING ITEMS....587
30 DISASSEMBLY AND ASSEMBLY....965
HOW TO USE THIS MANUAL....968
REMOVAL AND INSTALLATION OF COMPONANTS....968
SPECIAL TOOLS....968
REMOVAL....968
INSTALLATION....968
OVERHAUL OF COMPONANTS....969
SPECIAL TOOLS....969
DISASSEMBLY....969
ASSEMBLY....969
PRECAUTIONS WHEN CARRYING OUT AN OPERATION....970
SPECIAL TOOL LIST....972
SKETCH OF SPECIAL TOOLS....975
CONNECTOR REPAIR PROCEDURES....980
CONTACT TERMINAL REMOVAL (HD30 TYPE)....980
STRIPING INSULATION....981
CRIMPING CONTACT TERMINAL (HD30 TYPE)....982
INSERTION OF CONTACT TERMINAL (HD30 TYPE)....983
CONTACT TERMINAL REMOVAL (DT TYPE)....984
STRIPING INSULATION....985
CRIMPING CONTACT TERMINAL (DT TYPE)....986
INSERTION OF CONTACT TERMINAL (DT TYPE)....987
ENGINE ASSEMBLY....988
REMOVAL PROCEDURES....988
ENGINE INSTALLATION....995
RADIATOR, AFTERCOOLER AND OIL COOLER....997
RADIATOR REMOVAL PROCEDURES....997
RADIATOR INSTALLATION PROCEDURES....998
AFTERCOOLER REMOVAL PROCEDURES....998
AFTERCOOLER INSTALLATION PROCEDURES....1000
OIL COOLER REMOVAL PROCEDURES....1000
OIL COOLER INSTALLATION PROCEDURES....1002
COOLING FAN AND FAN MOTOR ASSEMBLY....1003
REMOVAL PROCEDURES....1003
INSTALLATION PROCEDURES....1004
FUEL TANK ASSEMBLY....1005
REMOVAL PROCEDURES....1005
INSTALLATION PROCEDURES....1007
TRANSFER ASSEMBLY....1008
REMOVAL PROCEDURES....1008
INSTALLATION PROCEDURES....1010
SPECIAL TOOLS....1011
DISASSEMBLY PROCEDURES....1011
ASSEMBLY PROCEDURES....1022
PARKING BRAKE ASSEMBLY....1036
REMOVAL PROCEDURES....1036
INSTALLATION PROCEDURES....1037
SPECIAL TOOLS....1038
DISASSEMBLY PROCEDURES....1038
ASSEMBLY PROCEDURES....1040
FRONT AXLE ASSEMBLY....1044
REMOVAL PROCEDURES....1044
INSTALLATION PROCEDURES....1046
REAR AXLE ASSEMBLY....1047
REMOVAL PROCEDURES....1047
INSTALLATION PROCEDURES....1049
FRONT AND REAR AXLE HOUSING....1051
SPECIAL TOOLS....1051
DISASSEMBLY PROCEDURES....1051
ASSEMBLY PROCEDURES....1057
DIFFERENTIAL CARRIER....1065
SPECIAL TOOLS....1065
DISSEMBLY PROCEDURES....1065
Disassembly Of Standard Differential Carrier....1071
Disassembly Of Anti-slip Differential....1073
ASSEMBLY PROCEDURES....1078
ASSEMBLY OF ANTI-SLIP DIFFERENTIAL....1078
ASSEMBLY OF STANDARD DIFFERENTIAL CARRIER....1082
HST AND 4-GEAR PUMP ASSEMBLY....1093
REMOVAL PROCEDURES....1093
INSTALLATION PROCEDURES....1095
HST MOTOR 1 ASSEMBLY....1096
REMOVAL PROCEDURES....1096
INSTALLATION PROCEDURES....1097
HST MOTOR 2 ASSEMBLY....1098
REMOVAL PROCEDURES....1098
INSTALLATION PROCEDURES....1099
WORK EQUIPMENT CONTROL VALVE....1100
REMOVAL PROCEDURES....1100
INSTALLATION PROCEDURES....1101
TRAVEL DAMPER VALVE....1102
REMOVAL PROCEDURES....1102
INSTALLATION PROCEDURES....1103
HYDRAULIC TANK....1104
REMOVAL PROCEDURES....1104
INSTALLATION PROCEDURES....1106
WORK EQUIPMENT....1107
REMOVAL PROCEDURES....1107
INSTALLATION PROCEDURES....1110
BUCKET LINK PIN....1110
BUCKET HINGE PIN....1111
BUCKET CYLINDER PIN (ON ROD SIDE)....1111
BOOM CYLINDER PIN (ON ROD SIDE)....1112
BOOM PIN (ON FRAME SIDE)....1112
BUCKET LINK PIN....1113
BELL CRANK CENTER PIN....1113
HST PUMP....1115
SPECIAL TOOLS LIST....1115
DISASSEMBLY PROCEDURES....1115
ASSEMBLY PROCEDURES....1128
HST MOTOR....1147
SPECIAL TOOLS LIST....1147
DISASSEMBLY PROCEDURES....1147
ASSEMBLY PROCEDURES....1158
HYDRAULIC CYLINDER....1167
SPECIAL TOOLS....1167
DISASSEMBLY PROCEDURES....1168
ASSEMBLY PROCEDURES....1170
OPERATOR'S CAB ASSEMBLY....1174
SPECIAL TOOLS....1174
REMOVAL PROCEDURES....1174
INSTALLATION PROCEDURES....1179
OPERATOR'S CAB GLASS....1180
SPECIAL TOOLS....1180
REMOVAL PROCEDURES....1180
INSTALLATION PROCEDURES....1181
COATING MATERIALS....1190
CENTER HINGE PIN....1191
SPECIAL TOOLS....1191
REMOVAL PROCEDURES....1191
INSTALLATION PROCEDURES....1198
REAR COUNTERWEIGHT....1204
REMOVAL PROCEDURES....1204
INSTALLATION PROCEDURES....1205
AIR CONDITIONER UNIT....1206
SPECIAL TOOLS....1206
REMOVAL PROCEDURES....1206
LOAD METER SPECIFICATION....1207
INSTALLATION PROCEDURES....1209
REFRIGERENT COMPRESSOR ASSEMBLY....1210
SPECIAL TOOLS....1210
REMOVAL PROCEDURES....1210
INSTALLATION PROCEDURES....1211
MONITOR PANEL....1212
REMOVAL PROCEDURES....1212
INSTALLATION PROCEDURES....1216
90 OTHERS....1217
HYDRAULIC CIRCUIT DIAGRAM....1218
ELECTRICAL CIRCUIT DIAGRAM....1219
STANDARD FLOOR HARNESS....1219
LIGHT SWITCH AND FRONT WIPER....1219
MONITOR CONTROLLER....1220
TO CAB HARNESS....1221
TO REAR AND BULKHEAD HARNESS....1222
TO HST HARNESS....1223
TO SHORT CONNECTOR....1224
TO HST CONTROLLER....1225
AIR CONDITIONER RELAY HARNESS....1226
JOINT CONNECTOR....1227
FLOOR HARNESS FOR LOAD METER....1228
LIGHT SWITCH AND FRONT WIPER....1228
MONITOR CONTROLLER....1229
TO CAB HARNESS....1230
TO REAR AND BULKHEAD HARNESS....1231
TO HST HARNESS....1232
TO KOMTRAX....1233
HST CONTROLLER....1234
AIR CONDITIONER RELAY HARNESS....1235
JOINT CONNECTOR....1236
HST AND BULK HEAD HARNESS....1237
GRILL HARNESS....1238
ENGINE AND POWER SUPPLY HARNESS....1239
CAB HARNESS....1240
EMERGENCY STEERING AND MULTI-FUNCTION HARNESS....1241
LOAD METER AND PRINTER HARNESS....1242
FRONT HARNESS....1243
REVERSE FAN WIRING DIAGRAM....1244
CEBM013602 - Parallel Tool Carrier WA320PT-5L Shop Manual....1246
CEBM013602 - WA320PT-5L S/N A39001 and up....1246
CONTENTS....1247
REVISION PAGES....1248
01 GENERAL....1278
GENERAL INFORMATION....1279
Machine Specifications....1280
Weight Table....1286
LUBRICANTS....1287
Ambient Temperature Range....1287
Recommended Lubricants....1288
Addtional Lubricant Information....1289
10 STRUCTURE AND FUNCTION....1290
ENGINE AND DRIVE SYSTEM....1295
Mounting....1295
Drive Dampener....1296
Outline....1296
Cooling System....1297
Specification....1297
Drive Line Componants....1298
Drive Line Flow....1299
Power Flow Outline....1300
Drive Shaft System....1301
Drive Shaft Outline....1301
HST HYDRAULIC SYSTEM....1302
Piping Diagram....1302
HST Pump (Hydro-static Transmission)....1303
Specifications....1303
Flow of Power....1304
Flow of Oil....1304
High Pressure Relief Valve....1305
Function....1305
Valve Operation....1306
Low Pressure Relief Valve....1307
Function....1307
Valve Operation....1307
HST Charge Pump....1308
Specifications....1308
Pump Outline....1308
Function....1308
Speed Related Valve (DA Valve)....1309
Function....1309
Valve Operation....1309
High Pressure Cut-off Valve....1310
Function....1310
Valve Operation....1310
HST MOTOR (HYDRO-STATIC TRANSMISSION)....1311
Motor 1....1311
Motor 1 Specifications....1311
Motor 2....1312
Motor 2 Specifications....1312
Principle....1313
Structure....1313
Operation....1313
PUMP VALVES....1314
EP Servo Valve....1314
Function....1314
Operation....1314
HA Servo Valve....1315
Function....1315
Operation....1315
Forward-Reverse Shuttle Valve....1316
Function....1316
Operation....1316
TRANSFER....1317
Outline....1318
Input Shaft....1320
Output Shaft....1322
Clutch Operation....1325
Low-Speed Mode....1326
Operation....1326
High-Speed Mode....1327
Operation....1327
CLUTCH SOLENOID VALVE....1328
Operation....1328
DRIVE AXLES....1329
Front Axle....1329
Front Differential....1330
Rear Axle....1333
Rear Differential....1334
Outline....1337
Torque Proportioning Differential....1338
Outline....1338
LIMITED-SLIP DIFFERENTIALS....1339
Front Differential....1339
Operation of Limited-Slip Differential....1340
Final Drive....1343
Outline....1344
AXLE MOUNTING AND CENTER HINGE....1345
Outline....1346
Center Hinge....1347
Axle Mount....1349
STEERING SYSTEM....1350
Steering Piping....1350
Steering Column....1351
Priority Valve....1352
Outline....1353
Operation....1353
Orbit-Roll Valve....1355
Outline....1356
Structure....1356
Cushion Valve....1362
Outline....1362
Function....1362
Steering Cylinder....1363
EMERGENCY STEERING....1365
Steering Piping....1365
Steering Valve....1366
BRAKING SYSTEM....1370
Brake Piping....1370
Brake Valve....1371
Outline....1372
Inching Valve....1375
Outline....1375
Charge Valve....1376
Function....1377
Operation....1378
Braking System Accumulator....1380
Function....1380
Specifications....1380
Slack Adjuster....1381
Function....1382
Operation....1382
Braking Unit....1383
Outline....1384
PARKING BRAKE....1385
Control....1385
Outline....1385
Parking Brake Unit....1386
Outline....1386
WORK EQUIPMENT....1387
Hydraulic Piping Layout WA320-5L....1387
Outline....1388
Hydraulic Piping Layout WA320PT-5L....1389
Outline....1390
Control Lever Linkage....1391
WA320-5L 2-Lever Type....1391
WA320PT-5L 3-Lever Type....1392
Multi-Function Joystick Type (WA320-5L)....1393
BASIC HYDRAULIC SYSTEM....1395
Hydraulic Tank....1395
Specifications....1396
Vent....1396
4-gear Pump Unit....1397
Outline....1397
Accumulator PPC Circuit....1399
Outline....1399
Specifications....1399
Lock Valve....1400
Outline....1400
Bypass Valve....1401
System Operation....1402
Quick Coupler Solenoid Valve....1404
Outline....1404
E. C. S. S. Valve....1405
ECSS Accumulator....1407
Function....1407
Specifications....1407
HYDRAULIC COOLING SYSTEM....1408
Piping Layout....1408
Outline....1408
Cooling Fan Motor....1409
Specifications....1409
Function....1410
Principle of Operation....1410
WORK EQUIPMENT CONTROL VALVE....1411
2-Spool Valve....1411
3-Spool Valve....1414
Relief Valve....1417
Function....1417
Operation....1417
Safety-suction Valve....1418
Function....1418
Operation as Safety Valve....1418
Suction Valve....1419
Function....1419
Operation....1419
Cut-Off Valve....1420
Function....1421
Operating Condition of Cut-Off Valve....1421
Work Equipment Controll Valve Operation....1424
WORK EQUIPMENT PPC VALVES....1430
2-Lever Type Valve....1430
Operation....1432
Attachment Lever Valve....1435
Operation....1436
Joystick Lever Type....1439
Operation....1441
WA320-5L MECHANICAL AND WORK EQUIPMENT....1445
Standard Work Equipment Bucket....1447
WA320PT-5L MECHANICAL AND WORK EQUIPMENT....1449
Optional Bucket....1451
Optional 1524 mm (60 inch) Construction Forks....1453
Optional 1371.6 mm (54 inch) Utility Forks....1454
Optional Extendable Boom....1455
Hydraulic Quick Coupler Group....1456
BUCKET POSITIONER, BOOM KICK-OUT AND DUMP SPEED....1457
WA320-5L Related System....1457
Outline....1458
Operation of Proximity Switch....1459
Function of Proximity Switch....1461
Function of Proximity Switch....1464
WA320PT-5L Related System....1465
Outline....1466
Operation of Proximity Switch....1466
WORK EQUIPMENT CYLINDERS....1475
WA320-5L....1475
Lift Cylinder....1475
Bucket Cylinder....1475
WA320PT-5L....1476
Lift Cylinder....1476
Bucket Cylinder....1476
Coupler Plunger....1476
HEATING AND AIR CONDITIONER PIPING....1478
MACHINE MONITERING SYSTEM....1479
Starting and Lighting Power Supply....1481
Speedometer Power Supply....1483
Load Meter Power Supply....1484
Sensor System Power Supply....1485
HST Safety Control Power Supply....1486
Preheat System Power Supply....1487
Load Meter Power Supply....1488
MACHINE MONITOR....1489
Standard Speedometer Display....1489
Optional Load Meter....1490
LIST OF ITEMS DISPLAYED ON MONITOR....1491
Service Mode Functions....1497
Outline....1497
Operating Method....1499
Spedometer Specifications....1499
Load Meter Specifications....1500
Items Related to the Fault History of Electrical System....1501
Items Related to the Fault History of Machine System....1504
Real-Time Monitor Function Speedometer Specification....1506
Real-Time Monitor Function Load Meter Specification....1509
Real-Time Monitoring Items....1513
Tuning Function....1517
Maintenance Functions....1519
Setting Required When Optional Device is Installed....1523
Function of Selecting Optional Device....1523
Function of Selecting Optional Device....1525
Load Meter Function....1529
Outline....1529
Operating Method....1529
Input/Ouput Signal....1539
Speedometer Specification....1539
HST SYSTEM ELECTRICAL CONTROLLER....1546
System Diagram....1546
Control Function....1547
HST Controller....1550
Input and Output Signals....1550
Selecting Directional Selector Switch (If Equipped)....1551
Outline....1551
Function....1551
Operation....1552
Engine Starting Circuit....1553
Function....1553
Operation....1553
Engine Stop Circuit....1555
Operation....1555
Automatic Preheating System....1556
Outline....1556
Operation....1556
Parking Brake Circuit....1557
Operation....1558
Electronically Controlled Suspension System....1560
Function....1560
Sensors....1561
Engine Speed Sensor....1561
Speed Sensor....1561
Engine Oil Pressure Sensor....1562
Fuel Level Sensor....1562
Coolant Temperature Sensor (For Monitor)....1563
Coolant Temperature Sensor (For Preheating)....1563
Axle Oil Temperature Sensor....1564
HST Sensor for Load Meter (Load Meter Specification)....1564
Emergency Steering Oil Pressure Sensor (If Equipped)....1565
HST Oil Filter Clogging Sensor....1565
Coolant Level Sensor....1566
Engine Oil Level Sensor....1567
Air Cleaner Clogging Sensor....1568
Lift Arm Angle Sensor (Load Meter Specification) (If Equipped)....1569
KOMTRAX SYSTEM....1571
KOMTRAX Terminal System....1571
KOMTRAX Terminal....1572
Input and Output Signals....1573
20 TESTING, ADJUSTING AND TROUBLESHOOTING....1574
STANDARD VALUE TABLE....1576
Engine....1576
Chassis....1577
SPECIAL TOOLS....1582
ENGINE COMPONENTS....1585
Measuring Exhaust Smoke....1585
Measuring Exhaust Temperature....1585
Adjusting Valve Clearance....1585
Measuring Compression Pressure....1585
Measuring Crankcase Pressure....1585
Measuring Engine Oil Pressure....1585
Measuring Boost Pressure....1585
Measuring Fuel Pressure....1585
Adjusting Engine Speed Sensor....1585
Bleeding Air From Fuel System....1585
Adjusting Engine Stop Solenoid....1585
Measuring Engine Speed....1586
Measuring Low And High Idle....1586
Measuring HST Stall Speed....1587
Measuring Hydraulic Stall....1587
Measuring Full Stall Speed....1587
ACCELERATOR PEDAL....1588
Testing Pedal Force....1588
Operating Angle of Pedal....1589
ADJUSTING ENGINE STOP SOLENOID....1590
ADJUSTING ENGINE SPEED SENSOR....1591
REFRIGERENT COMPRESSOR BELT....1592
DIRECTIONAL LEVER....1593
HST OIL PRESSURE....1594
Measuring....1594
Adjusting....1597
CLUTCH CONTROL PRESSURE....1599
STEERING WHEEL....1600
Measuring Steering Wheel End Play....1600
Measuring Operating Force on Steering Wheel....1600
Measuring Operating Time for Steering Wheel....1601
STEERING OIL PRESSURE....1602
Measuring Main Relief Pressure....1602
Adjusting Main Relief Pressure....1602
Bleeding Air From Steering Circuit....1603
HYDRAULIC FAN....1604
Measuring Fan Speed....1604
Measuring Oil Pressure....1604
MEASURING BRAKE PEDAL....1605
BRAKE PEDAL LINKAGE....1606
Testing....1606
Adjusting....1606
MEASURING BRAKE PERFORMANCE....1607
ACCUMULATOR CHARGE PRESSURE....1608
Measuring....1608
Adjusting....1608
BRAKE OIL PRESSURE....1609
MEASURING WEAR OF BRAKE DISC....1611
BLEEDING AIR FROM BRAKE CIRCUIT....1612
PARKING BRAKE PERFORMANCE....1613
PARKING BRAKE LINKAGE....1614
Testing....1614
Adjusting....1615
WORK EQUIPMENT CONTROL LEVER....1616
WORK EQUIPMENT PRESSURE....1617
Measuring....1617
Adjusting....1617
WORK EQUIPMENT PPC OIL PRESSURE....1619
Testing and Adjusting....1619
Bleeding Air....1621
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT....1622
BUCKET POSITIONER....1623
Testing....1623
Adjusting....1623
BOOM KICK-OUT....1624
PROXIMITY SWITCH ACTUATION DISPLAY LAMP....1625
PROCEDURE FOR CHECKING DIODE....1627
SPECIAL FUNCTIONS OF MACHINE MONITOR....1628
FLOW OF MODES AND FUNCTIONS....1629
SETTING MACHINE MONITOR (EMMS)....1645
REAL-TIME MONITORING ITEMS....1654
PM CLINIC INSPECTION CHART....1660
TROUBLESHOOTING (GENERAL)....1662
POINTS TO REMEMBER WHEN TROUBLESHOOTING....1663
SEQUENCE OF EVENTS IN TROUBLESHOOTING....1665
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE....1666
Precautions When Handling Electric Equipment....1666
Handling Control Box....1671
Points To Remember When Troubleshooting Electric Circuits....1672
Points To Remember When Handling Hydraulic Equipment....1673
CHECKS BEFORE TROUBLESHOOTING....1675
Using Troubleshooting Charts....1676
Phenomena Considered To Be Failures And Troubleshooting....1677
TABLE FOR CONNECTOR PIN NUMBERS....1680
T-ADAPTER TABLE....1703
CONNECTOR TYPES AND MOUNTING LOCATIONS....1706
CONNECTOR LAYOUT DRAWING....1712
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)....1718
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM....1719
Points To Remember If A Problem Returns To Normal....1719
User Code Memory Retention Function....1719
ERROR CODE AND POSSIBLE CAUSE TABLE....1720
FUSE SYSTEM CHECK....1722
Fuse Pannel Connection Table....1722
INFORMATION CONTAINED IN TESTING PROCEDURES....1723
Code Key Table....1724
[989F00]....1725
Transmission Protection Alert (00)....1725
[DHH1KX]....1727
HST Oil Pressure Signal Out Of Range....1727
[DLE2LC]....1729
Engine Speed Sensor Out Of Range....1729
[DW26KZ]....1731
Motor 2 Solenoid System Open Or Shorted....1731
[DX19KZ]....1735
Motor 1 Solenoid System Open Or Shorted....1735
Load Meter Specifications (If Equipped)....1737
[DX20KZ]....1740
Clutch Solenoid System Open Or Shorted....1740
Load Meter Specifications (If Equipped)....1743
[HST-1]....1747
Defective HST Power Controller Source....1747
[HST-2]....1751
Travel Speed Ranges Do Not Change....1751
[HST-3]....1755
Traction Control Inoperable....1755
[HST-4]....1757
Travel Speed Cannot Be Changed When Gear Selector Is In 1st....1757
[HST-5]....1760
Travel Speed Cannot Be Increased....1760
TROUBLESHOOTING OF TRAVEL DAMPENER SYSTEM (ECSS MODE)....1762
POINTS TO REMEMBER WHEN TROUBLESHOOTING....1763
Points To Remember If A Problem Returns To Normal....1763
User Code Memory Retention Function....1763
ECSS-1....1764
Travel Damper Dose Not Operate....1764
Travel Damper Does Not Reset....1767
TROUBLESHOOTING OF HST MONITOR SYSTEM (MON MODE)....1770
POINTS TO REMEMBER WHEN TROUBLESHOOTING....1774
Points To Remember If A Problem Returns To Normal....1774
User Code Memory Retention Function....1774
ERROR CODE AND POSSIBLE CAUSE TABLE....1775
FUSE SYSTEM CHECK....1777
Fuse Pannel Connection Table....1777
INFORMATION CONTAINED IN TESTING PROCEDURES....1778
Code Key Table....1779
[15B0NX]....1780
HST Oil Filter Showing Clogged Condition....1780
HST Load Meter Specifications (If Equipped)....1782
[2G42ZG]....1784
Low Accumulator Oil Pressure Indicated....1784
Load Meter Specifications (If Equipped)....1786
[989F00]....1788
Transmission Protection Caution Indicated....1788
[989FN1]....1789
HST Over-speed Condition....1789
[AA1ANX]....1790
Clogged Air Cleaner Indicated (Standard)....1790
Load Meter Specifications (If Equipped)....1792
[AB00L6]....1794
Defective Battery Charging Circuit....1794
Load Meter Specifications (If Equipped)....1796
[AB00MA]....1798
Defective Battery Charging Circuit....1798
Load Meter Specifications (If Equipped)....1800
[B@BAZG]....1802
Abnormal Engine Oil Pressure Indicated....1802
Load Meter Specifications (If Equipped)....1804
[B@BAZK]....1806
Abnormal Engine Oil Level Indication....1806
Load Meter Specifications (If Equipped)....1808
[B@BCNS]....1809
Engine Coolant Indicating Overheat Condition....1809
Load Meter Specifications (If Equipped)....1812
[B@BCZK]....1814
Abnormal Coolant Level Indication....1814
Load Meter Specifications (If Equipped)....1816
[B@C7NS]....1818
Brake Cooling Oil Indicating Overheating Condition....1818
Load Meter Specifications (If Equipped)....1820
[B@CRNS]....1822
HST Oil Showing Overheating Condition....1822
Load Meter Specifications (If Equipped)....1824
[D5ZHL6]....1826
Ignition Switch “C” (Ign) Input Failure Indicated....1826
Load Meter Specifications (If Equipped)....1828
[DAF3KK]....1831
With Ignition Switch On, Power Supply For Memory Is Off....1831
[DAF5KP]....1833
Defective 5-V Power Supply Output (KP)....1833
[DAF6KP]....1835
Defective 24-V Power Supply Output (KP)....1835
[DAF0KT]....1837
Controller Internal Failure....1837
[DAJ0KR]....1839
HST Controller Communication Failure....1839
Load Meter Specifications (If Equipped)....1841
[D182KZ]....1844
The Pre-heater Relay Coil Is Open Or Shorted....1844
[D1B0KB]....1846
HST Safety (Transmission Cut-off) Relay Open Or Shorted (KB)....1846
[DD1CLD]....1848
Defective Subtotal Switch....1848
[DD15LD]....1850
Monitor Panel Mode Selector Switch Will Not Set....1850
Load Meter Specifications (If Equipped)....1852
[DD16LD]....1854
Monitor Panel Mode Selector Switch Will Not Set....1854
Load Meter Specifications (If Equipped)....1856
[DD17LD]....1858
Monitor Panel Mode Selector Switch Will Not Set....1858
Load Meter Specifications (If Equipped)....1860
[DD18LD]....1862
Monitor Panel Mode Selector Switch Will Not Set....1862
Load Meter Specifications (If Equipped)....1864
[DDK3KB]....1866
Improper Input For Multiple Shift (FNR) Lever....1866
Load Meter Specifications (If Equipped)....1869
[DDS5L6]....1873
Decreased Steering Oil Pressure....1873
Load Meter Specifications (If Equipped)....1875
[DDY0LD]....1877
Defective Cancel Switch....1877
[DGE2KX]....1879
Engine Coolant Temperature Sensor Out Of Range....1879
Load Meter Specifications (If Equipped)....1881
[DGE3L6]....1883
Engine Coolant Temperature Sensor Out Of Range....1883
Load Meter Specifications (If Equipped)....1885
[DGH1KX]....1887
HST Oil Showing Overheating Condition....1887
load Meter Specifications (If Equipped)....1889
[DGR4KA]....1891
Axle Oil Indicating Short Circuit....1891
Load Meter Specifications (If Equipped)....1893
[DGR4KX]....1895
Brake Cooling Oil Indicating Open Circuit....1895
Load Meter Specifications (If Equipped)....1897
[DHE4L6]....1899
Engine Oil Pressure Indicating A Short Or Open In The System....1899
Load Meter Specifications (If Equipped)....1901
[DHPCKX]....1903
Possible Defective Bottom Pressure Sensor....1903
[DHPDKX]....1905
Possible Defective Rod Pressure Sensor....1905
[DKA0KX]....1907
Possible Defective Boom Angle Sensor....1907
[DV00KB]....1909
Possible Short Or Open In Alarm Buzzer....1909
[MON-1]....1911
Parking Brake Indicator Lamp Does Not Work....1911
Load Meter Specifications (If Equipped)....1915
[MON-2]....1920
Brake Oil Pressure Not Indicating Correctly....1920
Load Meter Specifications (If Equipped)....1922
[MON-3]....1924
Engine Coolant Sensor Not Indicating Correctly....1924
Load Meter Specifications (If Equipped)....1926
[MON-4]....1928
HST Oil Temperature Not Indicating Correctly....1928
[MON-5]....1932
Fuel Level Gauge Does Not Indicate Properly....1932
Load Meter Specifications (If Equipped)....1934
[MON-6]....1936
Abnormal Coolant Level Indication....1936
Load Meter Specifications (If Equipped)....1938
[MON-7]....1940
Steering Oil Pressure Not Reading Correctly....1940
Load Meter Specifications (If Equipped)....1942
[MON-8]....1944
Emergency Steering Oil Pressure Not Reading Correctly....1944
Load Meter Specifications (If Equipped)....1946
[MON-9]....1948
Monitor Panel Mode Selector Switch Will Not Set Correctly....1948
Load Meter Specifications (If Equipped)....1950
[MON-10]....1952
Monitor Panel Mode Selector Switch Will Not Set Correctly....1952
Load Meter Specifications (If Equipped)....1954
[MON-11]....1956
Monitor Panel Mode Selector Switch Will Not Set Correctly....1956
Load Meter Specifications (If Equipped)....1958
[MON-12]....1960
Monitor Panel Mode Selector Switch Will Not Set Correctly....1960
Load Meter Specifications (If Equipped)....1962
[MON-13]....1964
Alarm Buzzer Does Not Stop Or Remains ON....1964
Load Meter Specifications (If Equipped)....1966
[MON-14]....1968
Abnormal Engine Oil Level Indication....1968
Load Meter Specifications (If Equipped)....1970
[MON-15]....1972
Clogged Air Cleaner Indicated....1972
Load Meter Specifications (If Equipped)....1974
[MON-16]....1976
Defective Cancel Switch....1976
[MON-17]....1978
Defective Subtotal Switch....1978
[MON-18]....1980
Possible Defective Bottom Pressure Sensor....1980
[MON-19]....1982
Possible Defective Rod Pressure Sensor....1982
[MON-20]....1984
Front Windshield Wiper Does Not Work....1984
Rear Windshield Wiper Does Not Work....1986
[MON-21]....1988
Headlamps (Lo And High Beam) Does Not Function....1988
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)....1992
POINTS TO REMEMBER WHEN TROUBLESHOOTING....1994
Points To Remember If Abnormality Returns To Normal....1994
User Code Memory Retention Function....1994
FUSE SYSTEM CHECK....1995
Fuse Panel Connection Table....1995
INFORMATION CONTAINED IN TESTING PROCEDURES....1996
(E-1)....1998
Engine Will Not Crank....1998
When Directional Selector Actuation Switch Is Turned OFF....1998
When Directional Selector Actuation Switch Is Turned ON....2002
Defective Fuel Cut Solenoid System....2003
When Directional Selector Actuation Switch Is Turned ON (Load Meter Specification)....2010
Defective Fuel Cut Solenoid System (Load Meter Specification)....2011
(E-2)....2015
The Engine Does Not Shut Down....2015
(E-3)....2018
Cold Start Pre-heater Does Not Work Properly....2018
Preheating Does Not Work At All....2018
Preheat Is Constant....2020
Preheating Does Not Work At All (Load Meter Specification)....2023
Preheat Is Constant (Load Meter Specification....2025
(E-4)....2027
Parking Brake Does Not Function Properly....2027
Parking Brake Dragging (Prevention Does Not Function)....2027
(E-5)....2037
Boom Kick-out Function Not Working Properly....2037
(E-6)....2040
Bucket Lever Function Not Working Properly....2040
(E-7)....2043
Float Hold Function Not Working Properly....2043
(E-8)....2046
Travel Direction Does Not Change (“F” Machine Does Not Travel Forward)....2046
Travel Direction Does Not Change (“R” Machine Does Not Travel Reverse)....2048
(E-9)....2052
Front Windshield Wiper Does Not Work....2052
Rear Windshield Wiper Does Not Work....2056
(E-10)....2058
The Window Washer Does Not Work....2058
(E-11)....2060
Headlamps (Lo And High Beam) Does Not Function....2060
Headlamps (Lo Beam) Do Not Function....2065
Headlamps (Hi Beam) Do Not Function....2069
Clearance Lamps Do Not Function....2073
Turn Signals Do Not Function....2077
Work Lamps Do Not Function....2081
(E-12)....2085
Horn Does Not Sound....2085
(E-13)....2088
Air Conditioner System Does Not Work....2088
Air Does Not Flow From System And Cannot Be Adjusted....2091
Air Does Not Cool Or Temperature Cannot Be Adjusted....2095
Cannot Switch Between Circulated And Vent Functions....2099
Cannot Switch Vent Functions....2101
DEFECTIVE COOLING (MECHANICAL)....2104
DEFECTIVE HEATING (MECHANICAL)....2105
ABNORMAL NOISE IS HEARD FROM SYSTEM (MECHANICAL)....2106
WATER LEAKS FROM SYSTEM (MECHANICAL)....2107
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)....2108
METHOD OF USING TROUBLESHOOTING CHART....2110
FAILURE CODE AND CAUSE TABLE....2113
(H-1)....2115
The Machine Does Not Start....2115
(H-2)....2116
The Travel Speed Is Slow....2116
(H-3)....2117
The Thrust Force Is Weak....2117
(H-4)....2118
Engine Stalls Or Engine Speed Drops Excessively....2118
(H-5)....2119
The Gears Do Not Change Speed Range....2119
(H-6)....2120
The Steering Wheel Does Not Turn....2120
(H-7)....2121
Steering Wheel Movement Is Heavy....2121
(H-8)....2122
Steering Wheel Shakes Or Has Jerky Movement....2122
(H-10)....2123
Brakes Do Not Work Or Works Poorly....2123
(H-11)....2124
Brakes Is Not Releasing Or Dragged....2124
(H-12)....2125
The Lift Arm Does Not Rise Or Lower....2125
(H-13)....2126
Lift Arm Moves Slow Or Rising Force Is Poor....2126
(H-14)....2127
When Rising Lift Arm, Arm Moves Slowly At Specific Heights....2127
(H-15)....2127
The Lift Arm Cylinder Will Not Hold Down The Bucket (The Bucket Rises)....2127
(H-16)....2127
Hydraulic Drift On The Lift Arm Occurs Often....2127
(H-17)....2127
The Lift Arm Wobbles During Operation....2127
(H-18)....2128
When The Control Lever Is Switched From “Hold” To “Raise,” The Lift Arm Falls Temporarily....2128
(H-19)....2129
The Bucket Does Not Tilt Back....2129
(H-20)....2130
Bucket Moves Slow Or The Tilting-back Force Is Insufficient....2130
(H-21)....2131
The Bucket Operates Slowly In Tilting-back....2131
(H-22)....2131
Bucket Cylinder Cannot Hold Down The Bucket....2131
(H-23)....2131
Hydraulic Drifts Of The Bucket Occurs Often....2131
(H-24)....2132
The Bucket Wobbles During Travel With Cargo (The Work Equipment Valve Is Set To “Hold”)....2132
(H-25)....2132
When The Control Lever Is Switched From “Hold” To “Tilt,” The Bucket Falls Temporarily....2132
(H-26)....2133
Control Levers For The Lift Arm And Bucket Do Not Move Smoothly....2133
(H-27)....2134
Travel Damper Does Not Operate And Machine Pitches And Bounces....2134
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)....2136
METHOD OF USING TROUBLESHOOTING CHARTS....2137
(S-1) ENGINE STARTING PERFORMANCE IS POOR....2141
(S-2) ENGINE HAS STARTING PROBLEMS....2143
Engine Does Not Crank....2143
Engine Cranks But No Exhaust Smoke Comes Out Of Stack....2144
Smoke Comes Out Of Stack But Engine Does Not Start....2145
(S-3) ENGINE DOES NOT RUN SMOOTHLY....2146
(S-4) ENGINE STOPS DURING OPERATIONS....2147
(S-5) ENGINE SPEED HUNTS....2148
(S-6) ENGINE LACKS POWER....2149
(S-7) EXHAUST SMOKE IS BLACK....2150
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE....2151
(S-9) OIL BECOMES CONTAMINATED QUICKLY....2152
(S-10) FUEL CONSUMPTION IS EXCESSIVE....2153
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR....2154
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP....2155
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)....2156
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)....2157
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNUNG....2158
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING....2159
30 DISASSEMBLY AND ASSEMBLY....2160
HOW TO USE THIS MANUAL....2163
Removal And Installation Of Componants....2163
Special Tools....2163
Overhaul Of Componants....2164
Special Tools....2164
Disassembly....2164
Assembly....2164
PRECAUTIONS WHEN CARRYING OUT AN OPERATION....2165
SPECIAL TOOL LIST....2167
Sketch Of Special Tools....2171
CONNECTOR REPAIR PROCEDURES....2176
Contact Terminal Removal (HD30 Type)....2176
Striping Insulation....2177
Crimping Contact Terminal (HD30 Type)....2178
Insertion Of Contact Terminal (HD30 Type)....2179
Contact Terminal Removal (DT Type)....2180
Striping Insulation....2181
Crimping Contact Terminal (DT Type)....2182
Insertion Of Contact Terminal (DT Type)....2183
ENGINE ASSEMBLY....2184
Removal Procedures....2184
Engine Installation....2191
RADIATOR AND AFTER-COOLER....2193
Radiator Removal Procedures....2193
Radiator Installation Procedures....2194
Aftercooler Removal Procedures....2195
Aftercooler Installation Procedures....2196
Hydraulic Oil Cooler Removal Procedures....2197
COOLING FAN AND FAN MOTOR ASSEMBLY....2199
Removal Procedures....2199
Installation Procedures....2200
FUEL TANK ASSEMBLY....2201
Removal Procedures....2201
Installation Procedures....2203
TRANSFER ASSEMBLY....2204
Removal Procedures....2204
Installation Procedures....2206
TRANSFER ASSEMBLY OVERHAUL PROCEDURES....2207
Special Tools....2207
Disassembly Procedures....2207
Assembly Procedures....2218
PARKING BRAKE ASSEMBLY....2233
Removal Procedures....2233
Installation Procedures....2234
PARKING BRAKE ASSEMBLY OVERHAUL PROCEDURES....2235
Special Tools....2235
Disassembly Procedures....2235
Assembly Procedures....2237
FRONT AXLE ASSEMBLY....2241
Removal Procedures....2241
Installation Procedures....2243
REAR AXLE ASSEMBLY....2245
Removal Procedures....2245
Installation Procedures....2247
FRONT AND REAR AXLE HOUSING OVERHAUL PROCEDURES....2249
Special Tools....2249
Disassembly Procedures....2249
Assembly Procedures....2255
DIFFERENTIAL CARRIER OVERHAUL PROCEDURES....2263
Special Tools....2263
Dissembly Procedures....2263
DISASSEMBLY OF STANDARD CARRIER....2269
Disassembly Of Anti-slip Differential....2271
Assembly Procedures....2275
Assembly Of Anti-slip Differential....2275
Assembly of Standard Differential Carrier....2280
HST AND 4-GEAR PUMP ASSEMBLY....2291
Removal Procedures....2291
Installation Procedures....2293
HST MOTOR 1 ASSEMBLY....2295
Removal Procedures....2295
Installation Procedures....2296
HST MOTOR 2 ASSEMBLY....2297
Removal Procedures....2297
Installation Procedures....2298
WORK EQUIPMENT CONTROL VALVE ASSEMBLY....2299
Removal Procedures....2299
Installation Procedures....2300
TRAVEL DAMPER VALVE ASSEMBLY....2303
Removal Procedures....2303
Installation Procedures....2304
HYDRAULIC TANK ASSEMBLY....2305
Removal Procedures....2305
Installation Procedures....2307
HST PUMP OVERHAUL PROCEDURES....2309
Special Tools List....2309
Disassembly Procedures....2309
Assembly Procedures....2322
HST MOTOR OVERHAUL PROCEDURES....2341
Special Tools List....2341
Disassembly Procedures....2341
Assembly Procedures....2352
CYLINDERS....2361
Bucket (Tilt) Cylinder....2361
Removal....2361
Installation....2362
Boom (Lift) Cylinder....2363
Removal....2363
Installation....2364
CYLINDER OVERHAUL PROCEDURES....2365
Special Tools List....2365
Disassembly Procedures....2365
Assembly Procedures....2368
WORK EQUIPMENT ASSEMBLY....2373
Removal Procedures....2373
Installation Procedure....2377
Procedure For Installing Bucket Link Pin....2377
Procedure For Installing Bucket Hinge Pin....2378
Procedure For Installing Bucket Cylinder Pin (On Rod Side)....2378
Procedure For Installing Boom Cylinder Pin (On Rod Side)....2379
Procedure For Installing Boom Pin (On Frame Side)....2379
Procedure For Installing Bucket Link Pin....2380
Procedure For Installing Bell Crank Center Pin....2381
OPERATOR'S CAB ASSEMBLY....2383
Special Tools....2383
Removal Procedures....2383
Installation Procedures....2388
OPERATOR'S CAB GLASS....2389
Special Tools....2389
Removal Procedures....2389
Installation Procedures....2391
Coating Materials....2399
CENTER HINGE PIN....2400
Special Tools....2400
Removal Procedures....2400
Installation Procedures....2407
REAR COUNTERWEIGHT....2413
Removal Procedures....2413
Installation Procedures....2414
AIR CONDITIONER UNIT....2415
Special Tools....2415
Removal Procedures....2415
Load Meter Specification....2416
Installation Procedures....2418
REFRIGERENT COMPRESSOR ASSEMBLY....2419
Special Tools....2419
Removal Procedures....2419
Installation Procedures....2420
MONITOR PANEL....2421
Removal Procedures....2421
Installation Procedures....2426
HST CONTROLLER....2427
Removal Procedures....2427
Installation Procedures....2428
KOMTRAX TERMINAL ASSEMBLY....2429
Removal....2429
Installation....2430
90 OTHER....2432
HYDRAULIC CIRCUIT DIAGRAM....2433
ELECTRICAL CIRCUIT DIAGRAM....2435
STANDARD FLOOR HARNESS....2435
LIGHT SWITCH AND FRONT WIPER....2435
MONITOR CONTROLLER....2436
TO CAB HARNESS....2437
TO REAR AND BULKHEAD HARNESS....2438
TO HST HARNESS....2439
TO SHORT CONNECTOR....2440
TO HST CONTROLLER....2441
AIR CONDITIONER RELAY HARNESS....2442
JOINT CONNECTOR....2443
FLOOR HARNESS FOR LOAD METER....2444
LIGHT SWITCH AND FRONT WIPER....2444
MONITOR CONTROLLER....2445
TO CAB HARNESS....2446
TO REAR AND BULKHEAD HARNESS....2447
TO HST HARNESS....2448
TO KOMTRAX....2449
HST CONTROLLER....2450
AIR CONDITIONER RELAY HARNESS....2451
JOINT CONNECTOR....2452
HST AND BULK HEAD HARNESS....2453
GRILL HARNESS....2454
ENGINE AND POWER SUPPLY HARNESS....2455
CAB HARNESS....2456
EMERGENCY STEERING AND MULTI-FUNCTION HARNESS....2457
LOAD METER AND PRINTER HARNESS....2458
FRONT HARNESS....2459
Komatsu Wheel Loader GALEO WA320-L, Parallel Tool Carrier WA320PT-L Repair Service Manual
