Komatsu Wheel Loader WA320-LC Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA320-1LC, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loader WA320-1LC 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.
CEAMW19021 - Wheel Loader WA320-1LC Operation & Maintenance Manual.pdf
CEBMW19020 - Wheel Loader WA320-1LC Shop Manual.pdf
PRODUCT DETAILS:
Total Pages: 821 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
CEAMW19021 - Wheel Loader WA320-1LC Operation & Maintenance Manual....1
FOREWORD....5
INTRODUCTION....6
SAFETY INFORMATION....6
BREAKING IN THE NEW MACHINE....7
MACHINE AND ENGINE SERIAL NUMBERS....8
QUICK REFERENCE INFORMATION....9
CONTENTS....10
SAFETY PRECAUTIONS -- SECTION 1....19
GENERAL PRECAUTIONS....20
PERSONNEL PRECAUTIONS....20
MACHINE PRECAUTIONS....20
OPERATION....21
BEFORE STARTING....21
START-UP....22
GENERAL OPERATING PRECAUTIONS....22
DRIVING THE MACHINE....23
OPERATING THE ATTACHMENTS....24
PULLING/TOWING....24
SHUTDOWN....25
MAINTENANCE....25
GENERAL MACHINE PRECAUTIONS....25
GENERAL WORK PRECAUTIONS....26
ATTACHMENTS....27
ACCUMULATORS....27
BRAKES....27
CAB/ROPS....28
COOLING....28
ELECTRICAL....28
ENGINE....29
FUEL SYSTEM....29
HYDRAULICS....29
TIRES AND RIMS....30
TURBOCHARGER....30
VITON SEALS....30
SAFETY PRODUCT GRAPHICS AND LOCATIONS....31
BEFORE CARRYING OUT MAINTENANCE....43
OPERATION -- SECTION 2....45
GENERAL VIEW....46
INSTRUMENTS AND CONTROLS....47
MONITOR PANEL....47
CHECK MONITOR LAMP GROUP....47
CAUTION MONITOR LAMP GROUP....47
METER GROUP....48
WARNING LAMP....48
SYSTEM CHECK....48
CHECK MONITOR LAMP GROUP....49
Engine Oil Level Monitor....49
Coolant Level Monitor....50
CAUTION MONITOR LAMP GROUP....50
Battery charge monitor....51
Fuel level monitor....51
Brake system failure monitor....52
Engine oil pressure monitor....53
Coolant level monitor....53
Brake pressure monitor....53
Coolant temperature monitor....54
Torque converter oil temperature monitor....54
Ground driven steering monitor - if equipped....54
METER GROUP....55
Parking brake pilot lamp....55
Pilot lamp for working lamp....56
Transmission cut-off selector pilot lamp....56
Ground driven steering pilot lamp - if equipped....56
Engine cooling water temperature gauge....56
Torque converter oil temperature gauge....57
Fuel gauge....57
Turn signal pilot lamp....57
High beam pilot lamp....57
Speedometer....58
Service meter....58
SWITCHES....59
WORKING LAMP SWITCH....59
STARTING SWITCH....60
HAZARD LAMP SWITCH....60
HORN BUTTON....60
LAMP SWITCHES....61
Lamp switch....61
Turn signal lever....61
Dimmer switch....61
TRANSMISSION CUT-OFF SELECTOR SWITCH....62
ETHER START SWITCH....62
FRONT WIPER SWITCH....63
REAR WIPER SWITCH....63
WINDOW WASHER SWITCH....64
FRONT FLOOD LIGHT SWITCH....64
ACCESSARY SWITCH....64
ROOM LAMP SWITCH....64
ClGARETTE LIGHTER....65
LEVERS AND PEDALS....66
DIRECTIONAL LEVER....66
SPEED CONTROL LEVER....67
SPEED CONTROL LEVER STOPPER....67
STEERING COLUMN TILT LEVER....67
ACCELERATOR PEDAL....68
BRAKE PEDALS....68
Right brake pedal....68
Left brake pedal....68
LIFT ARM CONTROL LEVER....69
BUCKET CONTROL LEVER....69
WORK EQUIPMENT CONTROL LEVERS LOCK....70
PARKING BRAKE LEVER....70
WORK EQUIPMENT CONTROL LEVER....71
MON-LEVER TYPE....71
CAB DOOR HOLD OPEN LOCK - IF EQUIPPED....72
AIR CLEANER SERVICE INDICATOR....72
FRAME LOCKING BAR....72
HOOD TILT LOCK....73
MAIN CIRCUIT....73
FUSE BOXES....74
OPERATOR'S SEAT....76
RIGID TYPE....76
FORWARD-BACKWARD ADJUSTMENT....76
SEAT HEIGHT ADJUSTMENT....76
BACKREST ADJUSTMENT....76
BUCKET TYPE SEAT (OPT)....76
FORWARD-BACKWARD ADJUSTMENT....76
SEAT ANGLE ADJUSTMENT....76
SEAT CUSHION ADJUSTMENT....76
BACKREST ADJUSTMENT....76
SEAT HEIGHT ADJUSTMENT....76
SEARS SEAT....77
FORWARD-BACKWARD ADJUSTMENT....77
SEAT ANGLE ADJUSTMENT....77
WEIGHT ADJUSTMENT....77
BACKREST TILT ADJUSTMENT....77
HEIGHT ADJUSTMENT....77
KAB SEAT....78
WEIGHT ADJUSTMENT....78
HEIGHT ADJUSTMENT....78
BACKREST ANGLE ADJUSTMENT....78
FORE AND AFT ADJUSTMENT....78
HEADREST ADJUSTMENT (IF EQUIPPED)....78
RIGHT SIDE ARMREST....79
SEAT BELT....80
DRAWBAR PIN....81
CAB HEATER AND DEFROSTER ....82
CONTROL PANEL....82
FAN SPEED SWITCH....82
FOOT / DEFROSTER SELECT LEVER....82
AIR INTAKE SELECTOR LEVER....82
CONTROL PANEL....83
FAN SPEED SWITCH....83
TEMPERATURE CONTROL LEVER....83
AIR INTAKE SELECTOR LEVER....83
METHOD OF OPERATION....84
CAB HEATER, DEFROSTER AND AIR CONDITIONER - IF EQUIPPED....85
CONTROL PANEL....85
FAN SPEED SWITCH....85
AIR CONDITIONER SWITCH....85
TEMPERATURE CONTROL LEVER....85
AIR INTAKE SELECTOR LEVER....85
METHOD OF OPERATION....86
PRECAUTIONS FOR USING AIR CONDITIONER....87
HANDLING AIR CONDITIONER IN SEASON....87
HANDLING AIR CONDITIONER IN OFF-SEASONS....87
LOCKING FILLER CAPS....88
FUEL TANK FILLER CAP....88
HYDRAULIC TANK FILLER CAP....89
CHECK BEFORE STARTING....90
WALK-AROUND CHECK....90
CHECK MONITOR PANEL....90
CHECK AND REFILL COOLANT....91
CHECK AIR CLEANER SERVICE INDICATOR....91
CHECK OIL LEVEL AND REFILL IN ENGINE OIL PAN....92
CHECK FUEL LEVEL AND REFILL FUEL....92
DRAIN THE WATER FROM THE FUEL-WATER SEPARATOR....93
ADDITIONAL CHECKS....93
CHECK ELECTRICAL WIRING....93
OPERATING YOUR MACHINE....95
BEFORE STARTING THE ENGINE....95
STARTING ENGINE....96
SPECIAL STARTING....97
COLD WEATHER STARTING....97
COLD WEATHER WARM-UP PROCEDURE....99
CHECKS AFTER STARTING....100
MOVING MACHINE OFF....100
SHIFTING GEAR....102
SHIFTING BETWEEN FORWARD AND REVERSE....102
STEERING MACHINE....103
TO STOP THE MACHINE....104
TO STOP THE ENGINE....105
OPERATIONS AFTER STOPPING ENGINE....105
OPERATIONAL PRECAUTIONS....106
WORKING IN DUSTY LOCATIONS....106
MAXIMUM DEPTH OF WATER....106
IF WHEEL BRAKE DOES NOT WORK....107
PRECAUTIONS WHEN DRIVING UP OR DOWN SLOPES....107
LOWER THE CENTER OF GRAVITY WHEN TURNING....107
BRAKING ON DOWNHILL SLOPES....107
IF ENGINE STOPS....107
POSSIBLE WORK USING LOADER....108
EXCAVATION....108
LEVELING....110
LOAD AND CARRY OPERATlONS....111
LOADING....111
Cross Drive Loading....111
V-Shape Loading....111
PARKING MACHINE....112
ADJUSTMENT OF WORK EQUIPMENT....113
ADJUSTING BOOM KICKOUT....113
ADJUSTING BUCKET POSITIONER....114
BUCKET LEVEL INDICATOR....114
HANDLING TIRES....115
PRECAUTIONS WHEN HANDLING TIRES....115
PRECAUTIONS WHEN DRIVING MACHINE....115
TIRE PRESSURE....115
TOWING....118
TOWING THE MACHINE....118
WHEN ENGINE CAN BE USED....118
WHEN ENGINE CANNOT BE USED....118
TRANSPORTATION....118
COLD WEATHER OPERATION....119
PREPARATION FOR LOW TEMPERATURE....119
FUEL AND LUBRICANTS....119
COOLANT....119
BATTERY....119
CAUTIONS AFTER COMPLETION OF WORK....119
AFTER COLD WEATHER....120
LONG TERM STORAGE....120
BEFORE STORAGE....120
DURING STORAGE....120
AFTER STORAGE....120
HANDLING OF BATTERY....121
PRECAUTIONS FOR CHARGING BATTERY....121
REMOVAL AND INSTALLATION OF BATTERY....121
STARTING ENGINE WITH BOOSTER CABLES....121
BEFORE CONNECTING BOOSTER CABLES....121
CONNECTING BOOSTER CABLES....122
STARTING ENGINE....122
DISCONNECTING BOOSTER CABLES....122
TROUBLESHOOTING....123
ELECTRICAL SYSTEM....123
ENGINE....124
CHASSIS....125
TRANSMISSION....125
DRIVE AXLES....125
WHEEL BRAKES....125
PARKING BRAKE....125
STEERING....125
EQUIPMENT HYDRAULIC SYSTEM....125
MAINTENANCE -- SECTION 3....127
PERIODIC MAINTENANCE....128
MAINTENANCE GUIDELINES....128
OUTLINES OF SERVICE....129
LUBRICATION WHEN SHIPPED....129
RELATING TO ENGINE....130
ENGINE OIL....130
COOLANT....130
DIESEL FUEL....130
RELATING TO HYDRAULIC SYSTEM....130
RELATING TO ELECTRICAL SYSTEM....130
RELATING TO LUBRICATION....131
BLEEDING AIR....131
BLEEDING AIR FROM HYDRAULIC TANK....131
BLEEDING AIR FROM THE WHEEL BRAKE HYDRAULIC CIRCUIT....132
BLEEDING AIR FROM FUEL SYSTEM....133
WEAR PARTS REPLACEMENT....135
PERIODICAL PART REPLACEMENT....135
LUBRICANTS, FUEL AND COOLANT....136
PROPER SELECTION TABLE....136
ENGINE OIL....137
Normal Operation....137
Arctic Operation....137
AXLE OIL....138
GREASE....138
DIESEL FUEL....138
COOLANT....138
SCHEDULED MAINTENANCE GUIDE....145
OIL FILLER AND LEVEL GAUGE POSITIONS....150
INITIAL 250 HOURS SERVICE ONLY....150
TRANSMISSION OIL FILTER....150
WHEN REQUIRED....151
COOLANT ADDITIVE CONCENTRATION - DCA4....151
AIR CLEANER ELEMENT....151
CHECKING....151
CLEANING OR REPLACING OUTER ELEMENT....152
REPLACING INNER ELEMENT....152
CLEANING OUTER ELEMENT....153
TRANSMISSION OIL....154
RADIATOR CORE....154
WINDSHIELD WASHER TANKS....155
DRIVE AXLE OIL....155
DRIVE AXLE HOUSING BREATHERS....156
LUBRICATING....157
BUCKET BOLT-ON CUTTlNG EDGE - IF EQUIPPED....159
BUCKET TEETH - IF EQUIPPED....159
BUCKET IS EQUIPPED WITH BOLT-ON TEETH....159
BUCKET IS EQUIPPED WITH WELDED ON OR REPLACEABLE TIP TEETH....160
PARKING BRAKE....161
INSPECTION....161
ADJUSTMENT....161
LENGTH OF LEVER....162
AIR CONDITIONER CONDENSER - IF EQUIPPED....162
AIR CONDITIONER REFRIGERANT CHARGE - IF EQUIPPED....163
STEERING....164
HYDRAULIC SYSTEM....164
SERVICE METER....164
CHECK BEFORE STARTING....165
EVERY 50 HOURS SERVICE....165
FUEL TANK....165
TIRES....165
EVERY 100 HOURS SERVICE....165
HYDRAULIC TANK....165
LUBRICATING....166
CAB AIR FILTER - IF EQUIPPED....166
AIR CONDITIONER FILTER - IF EQUIPPED....166
TRANSMISSION CASE....167
EVERY 250 HOURS SERVICE....168
LUBRICATING....168
WHEEL HUB BOLTS....171
ENGINE OIL PAN AND FILTER....171
BATTERY ELECTROLYTE....172
AIR INTAKE SYSTEM....173
AIR CONDITIONER COMPRESSOR DRIVE BELT - IF EQUIPPED....173
COOLANT FILTER....174
EVERY 500 HOURS SERVICE....175
LUBRICATING....175
FUEL FILTERS....175
GENERAL....175
REPLACEMENT....175
TRANSMISSION OIL FILTER....177
ANTIFREEZE CONCENTRATION....177
AIR DRYER - IF EQUIPPED....178
EVERY 1000 HOURS SERVICE....178
LUBRICATING....178
TRANSMISSION CASE BREATHER....180
TRANSMISSION OIL AND STRAINER....180
ENGINE VALVES....181
DRIVE BELT....185
DRIVE BELT, TENSIONER BEARING AND FAN HUB....185
EVERY 2000 HOURS SERVICE....187
DRIVE AXLES....187
HYDRAULIC TANK BREATHER....188
HYDRAULIC TANK AND FILTER....189
BRAKE DISC....190
VIBRATION DAMPER....190
COOLING SYSTEM....191
AIR CONDITIONER FILTER - IF EQUIPPED....193
ACCUMULATOR....193
SPECIFICATIONS -- SECTION 4....195
GENERAL SPECIFICATIONS....196
STANDARD TIGHTENING TORQUES....201
STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS....201
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS....201
TIGHTENING TORQUE FOR NUTS OF FLARED FllTlNGS....202
UNIT CONVERSIONS....203
AREA....204
DENSITY (Mass Density)....204
FORCE....205
FORCE PER LENGTH....205
HEAT....205
LENGTH....206
MASS (WEIGHT)....206
POWER....207
PRESSURE....207
TEMPERATURE....207
TEMPERATURE INTERVAL OR TOLERANCE....208
VOLUME....208
TORQUE....209
VELOCITY....209
CEBMW19020 - Wheel Loader WA320-1LC Shop Manual....212
CONTENTS....218
10 ENGINE....232
12 TESTING AND ADJUSTING....232
STANDARD VALUE TABLE ....233
TOOL LIST FOR TESTING AND ADJUSTING ....236
VALVE CLEARANCE....238
FUEL INJECTION TIMING ....239
ENGINE OIL PRESSURE AND TEMPERATURE ....240
BLOW-BY PRESSURE ....242
EXHAUST GAS COLOR ....243
ACCELERATOR PEDAL, OPERATING FORCE AND OPERATING ANGLE ....244
13 DISASSEMBLY AND ASSEMBLY....248
STARTING MOTOR ....250
REMOVAL....250
INSTALLATION....250
ALTERNATOR ....251
REMOVAL....251
INSTALLATION....251
OIL COOLER....252
REMOVAL....252
INSTALLATION....252
FUEL INJECTION PUMP....253
REMOVAL....253
INSTALLATION....253
WATER PUMP....254
REMOVAL....254
INSTALLATION....254
INJECTORS....255
REMOVAL....255
INSTALLATION....256
TURBOCHARGER ....257
REMOVAL....257
INSTALLATION....258
CYLINDER HEAD....259
REMOVAL....259
INSTALLATION....260
RADIATOR ....261
REMOVAL....261
INSTALLATION....263
ENGINE....265
REMOVAL....265
INSTALLATION....270
FUEL TANK ....275
REMOVAL ....275
INSTALLATION....276
14 MAINTENANCE STANDARD....278
ENGINE MOUNT ....279
RADIATOR AND TORQUE CONVERTER OIL COOLER ....280
20 POWER TRAIN....282
21 STRUCTURE AND FUNCTION....282
GENERAL....283
HYDRAULIC CIRCUIT FOR POWER TRAIN....287
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN....288
TORQUE CONVERTER AND TRANSMISSION PIPING....289
TORQUE CONVERTER CHARGING PUMP ....290
TORQUE CONVERTER....291
TORQUE CONVERTER OIL FILTER....292
TRANSMISSION ....293
CLUTCH PACK....295
FORWARD AND REVERSE CLUTCH....295
1ST, 3RD CLUTCH....295
2ND, 4TH CLUTCH....296
CONTROL VALVE....297
SOLENOID VALVE....298
UPPER VALVE....299
LOWER VALVE....300
PRIORITY AND MAIN REGULATOR VALVE....301
MAIN REGULATOR VALVE....302
TORQUE CONVERTER OIL OUTLET VALVE....303
PILOT REDUCING VALVE....304
SOLENOID VALVE....305
FILL VALVE....306
MODULATING RELIEF VALVE, ACCUMULATOR VALVE, QUICK RETURN VALVE....308
DIRECTIONAL SPOOL....312
EMERGENCY MANUAL SPOOL....313
PILOT OIL FILTER....314
AXLE MOUNT....315
AXLE....317
FRONT....317
REAR....318
DIFFERENTIAL....319
FINAL DRIVE....320
TIRE AND WHEEL....321
22 TESTING AND ADJUSTING....322
STANDARD VALUE TABLE ....323
TOOL LIST FOR TESTING AND ADJUSTING ....324
ENGINE STALL SPEED....325
MEASURING OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION....327
SHIFT LEVER ....330
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL ....331
TIRE AND WHEEL....333
TROUBLESHOOTING....334
PRECAUTIONS WHEN TROUBLESHOOTING....335
METHOD OF READING TROUBLESHOOTING TABLES....337
PREVENTING RECURRENCE OF TROUBLE....339
CHECKS BEFORE TROUBLESHOOTING....340
JUDGEMENT ON POWER TRAIN....341
TROUBLESHOOTING TABLE....343
1. Machine does not move.....343
2. Machine speed is low, thrust is weak, gradeability falls off.....345
3. Large shock when moving off or changing gear.....347
4. Large time lag when moving off or changing gear.....348
5. Oil temperature in torque converter is high.....349
23 DISASSEMBLY AND ASSEMBLY ....350
TORQUE CONVERTER CHARGING PUMP ....352
REMOVAL....352
INSTALLATION....352
TRANSMISSION, TORQUE CONVERTER ....353
REMOVAL....353
INSTALLATION....359
TORQUE CONVERTER ....365
DISASSEMBLY ....365
ASSEMBLY....368
TRANSMISSION....371
DISASSEMBLY....371
ASSEMBLY....378
CLUTCH PACK....389
DISASSEMBLY....389
FORWARD-REVERSE CLUTCH PACK....389
1ST-3RD SPEED CLUTCH PACK....391
2ND-4TH SPEED CLUTCH PACK....393
ASSEMBLY....395
FORWARD-REVERSE CLUTCH PACK....396
1ST-3RD SPEED CLUTCH PACK....401
2ND-4TH SPEED CLUTCH PACK....405
TRANSMISSION CONTROL VALVE ....409
REMOVAL ....409
INSTALLATION....410
TRANSMISSION SOLENOID VALVE....416
DISASSEMBLY....416
ASSEMBLY....416
DIFFERENTIAL....417
DISASSEMBLY....417
ASSEMBLY....421
FRONT AXLE....432
REMOVAL....432
INSTALLATlON....434
REAR AXLE ....436
REMOVAL....436
INSTALLATION....439
DRIVE SHAFT ....442
DISASSEMBLY....442
ASSEMBLY....444
AXLE HOUSING ....446
DISASSEMBLY....446
ASSEMBLY....451
24 MAINTENANCE STANDARD ....458
ENGINE AND TRANSMISSION MOUNT....459
TORQUE CONVERTER CHARGING PUMP ....461
TORQUE CONVERTER....462
TRANSMISSION....463
TRANSMISSION CONTROL VALVE....466
UPPER VALVE....466
LOWER VALVE....468
SOLENOID VALVE....469
TRANSMISSION CLUTCH....470
DIFFERENTIAL....473
FINAL DRIVE....475
DRIVE SHAFT....477
AXLE MOUNT....478
AXLE....480
40 STEERING SYSTEM....484
41 STRUCTURE AND FUNCTION....484
HYDRAULIC PIPING....485
HYDRAULIC CIRCUIT SCHEMATICS....485
HYDRAULIC CIRCUIT DIAGRAM....487
2-SPOOL....487
3-SPOOL (WITH GROUND STEERING) DRJEN....488
3-SPOOL (WITH GROUND DRIVEN STEERING, SECURITY VALVE)....489
STEERING CONTROL SYSTEM ....490
STEERING VALVE (ORBITROL VALVE) ....490
PRIORITY VALVE....497
HAND PUMP AND SLEEVE....500
CUSHION VALVE....502
GROUND DRIVEN STEERING PUMP....503
DIVERTER VALVE....504
STEERING COLUMN ....507
STEERING CYLINDER MOUNT AND CENTER HINGE PIN ....508
42 TESTING AND ADJUSTING....510
STANDARD VALUE TABLE FOR CHASSIS....511
TOOL LIST....511
STEERING WHEEL....512
PLAY....512
OPERATING FORCE....513
OPERATING TIME - LOCK TO LOCK....514
STEERING OIL PRESSURE....515
TROUBLESHOOTING....516
STEERING SYSTEM....517
1. Steering wheel does not turn.....517
2. Steering wheel is sluggish.....518
3. Steering wheel moves unsteadily or is subjected to large shock.....519
43 DISASSEMBLY AND ASSEMBLY....520
STEERING VALVE....521
REMOVAL....521
INSTALLATION....523
DISASSEMBLY....526
ASSEMBLY....529
PRIORITY VALVE....534
REMOVAL....534
INSTALLATION....536
STEERING CYLINDER....538
REMOVAL....538
INSTALLATION....539
DISASSEMBLY....540
ASSEMBLY....542
CENTER HINGE PIN....545
REMOVAL....545
INSTALLATlON....550
44 MAINTENANCE STANDARD....556
STEERING COLUMN ....557
STEERING CYLINDER MOUNT....558
CENTER HINGE PIN....558
STEERING PUMP....561
PRIORITY VALVE....562
GROUND DRIVEN STEERING....563
50 BRAKE SYSTEM....564
51 STRUCTURE AND FUNCTION....564
BRAKE CONTROL SYSTEM....565
SYSTEM DIAGRAM....565
BRAKE CIRCUIT DIAGRAM....566
BRAKE CIRCUIT SCHEMATICS....567
CHARGE VALVE....568
ACCUMULATOR....572
BRAKE VALVE....573
PRESSURE CONTROL VALVE....574
SAFETY VALVE....575
BRAKE....576
PARKING BRAKE....577
BRAKE CALIPER....578
52 TESTING AND ADJUSTING....580
STANDARD VALUE TABLE....581
TOOL LIST....582
BRAKE PEDAL....583
BRAKE PEDAL LINKAGE....584
BRAKE PERFORMANCE....585
BRAKE PISTON LEAKAGE....586
BRAKE DISC....587
AIR BLEEDING....588
ACCUMULATOR CIRCUIT....588
FRONT AXLE BRAKE CIRCUIT....589
REAR AXLE BRAKE CIRCUIT....589
PARKING BRAKE....590
PERFORMANCE....590
CHECKING AND ADJUSTING....591
CLEARANCE....593
53 DISASSEMBLY AND ASSEMBLY....594
BRAKE VALVE....595
REMOVAL....595
INSTALLATION....596
DISASSEMBLY....597
ASSEMBLY....598
PARKING BRAKE....599
REMOVAL....599
INSTALLATION....601
PARKING BRAKE PAD....603
REMOVAL....603
INSTALLATION....603
ACCUMULATOR....604
REMOVAL....604
INSTALLATION....604
DISASSEMBLY....605
ASSEMBLY....605
54 MAINTENANCE STANDARD....608
BRAKE....609
PARKING BRAKE....610
BRAKE VALVE....611
60 WORK EQUIPMENT SYSTEM....612
61 STRUCTURE AND FUNCTION....612
HYDRAULIC PIPING....613
HYDRAULIC CIRCUIT DIAGRAMS....614
HYDRAULIC TANK....616
OIL FILTER BYPASS VALVE....617
BREATHER....618
HYDRAULIC AND STEERING PUMPS....619
HYDRAULIC VALVES....620
SECURITY VALVE....620
PRIORITY VALVE....621
RELIEF VALVE....622
SAFETY VALVE (WITH SUCTION VALVE)....623
SUCTION VALVE....624
MAIN CONTROL VALVE....625
2-SPOOL....625
3-SPOOL....627
OPERATION....629
HYDRAULIC CYLINDER....635
LIFT CYLINDER....635
DUMP CYLINDER....635
STEERING CYLINDER....635
BUCKET LINKAGE....636
WORK EQUIPMENT LEVER LINKAGE....638
62 TESTING AND ADJUSTING....640
STANDARD VALUE TABLE ....642
TOOL LIST....643
DUMP AND LIFT CONTROL LEVERS ....644
HYDRAULIC CIRCUIT FLUSHING ....646
HYDRAULIC PRESSURE ....649
LIFT ARM AND BUCKET ....651
HYDRAULIC DRIFT OF LIFT ARM AND BUCKET ....653
BUCKET POSITIONER....654
BOOM KICK-OUT ....656
TROUBLESHOOTING....658
TROUBLESHOOTING TABLES....659
1. Lift arm does not rise.....659
2. Lift arm moves slowly or does not have sufficient lifting power.....660
3. Lift arm movement becomes slow after it reaches a certain height.....661
4. Bucket cannot be held down with lift arm cylinder.....661
5. Lift arm has large hydraulic drift.....661
6. Lift arm movement is unsteady during work.....661
7. Lift arm descends momentarily when control lever is shifted from "Hold" to "Raise".....661
8. Bucket does not tilt back.....662
9. Bucket moves slowly or has insufficient tilt back power.....663
10. Bucket movement becomes slow during tilt back.....664
11. Bucket cannot be held down by the dump cylinder.....664
12. Bucket has large hydraulic drift.....664
13. Bucket moves unsteadily when machine travels under load. (Main control valve in "Hold")....664
14. Bucket dumps momentarily when control lever is shifted from "Hold" to "Tilt back".....664
15. Control levers of lift arm and bucket move stiffly and sluggishly.....665
63 DISASSEMBLY AND ASSEMBLY....666
HYDRAULIC TANK ....667
REMOVAL....667
INSTALLATION....670
HYDRAULIC FILTER ....672
REMOVAL....672
INSTALLATION....672
HYDRAULIC & STEERING PUMP....673
REMOVAL....673
INSTALLATION....674
MAIN CONTROL VALVE ....675
REMOVAL....675
INSTALLATION....677
DISASSEMBLY....678
ASSEMBLY....680
DUMP CYLINDER....682
REMOVAL....682
INSTALLATION....684
LlFT CYLINDER....685
REMOVAL....685
INSTALLATION....686
HYDRAULIC CYLINDER....687
DISASSEMBLY....687
ASSEMBLY....689
WORK EQUIPMENT....692
REMOVAL....692
INSTALLATION....695
COUNTERWEIGHT....698
REMOVAL....698
INSTALLATION....698
64 MAINTENANCE STANDARD....700
HYDRAULIC AND STEERING PUMPS....701
GROUND DRIVEN STEERING PUMP....702
PRIORITY VALVE....703
MAIN CONTROL VALVE....705
2-SPOOL....705
3-SPOOL....707
CYLINDER....709
STEERING CYLINDER....709
LIFT CYLINDER....709
DUMP CYLINDER....709
BUCKET LINKAGE....711
BUCKET....715
WITH TOOTH....715
WITH B.O.C.....715
BUCKET POSITIONER AND BOOM KICK-OUT....716
80 ELECTRIC AND ELECTRONIC SYSTEM....718
81 STRUCTURE AND FUNCTION....718
ELECTRICAL FOLDOUT....719
ENGINE STARTING CIRCUIT....720
SAFETY RELAY....721
ENGINE STOP CIRCUIT....722
ELECTRICAL TRANSMISSION CONTROL....723
COMBINATION SWITCH....724
TRANSMISSION CUT-OFF SELECTOR SWITCH....725
NEUTRALIZER RELAY....726
KICK-DOWN SWITCH....727
KICK-DOWN ELECTRICAL CIRCUIT....728
BUCKET POSITIONER AND BOOM KICK-OUT....736
PROXIMITY SWITCH....738
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)....742
MONITOR PANEL....743
INDICATION ON MONITOR PANEL....744
SENSORS, SWITCHES....746
SENSOR, SWITCH ACTUATION TABLE....746
BRAKE PRESSURE SWITCH....747
BRAKE DIFFERENTIAL PRESSURE WARNING SWITCH....747
COOLANT LEVEL SENSOR....748
TORQUE CONVERTER OIL TEMPERATURE SENSOR....748
ROTATIONAL SPEED SENSOR....749
FUEL LEVEL SENSOR....750
82 TESTING AND ADJUSTING....752
SPEEDOMETER MODULE....754
TROUBLESHOOTING....756
PRECAUTION WHEN HANDLING CONNECTOR....757
CONNECTOR TERMINAL NUMBERS....759
POSITION OF CONNECTORS FOR TROUBLESHOOTING....764
ELECTRICAL CIRCUIT SYSTEM....769
ENGINE STARTING CIRCUIT SYSTEM....769
ENGINE STOP CIRCUIT SYSTEM....770
TRANSMISSION CONTROL AND PARKING BRAKE SYSTEM....771
ELECTRICAL CN AND THREE DIMENSIONAL VIEW DIAGRAM....772
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART....773
TROUBLESHOOTING TABLES....776
E-1 ENGINE DOES NOT START.....777
E-2 ENGINE DOES NOT STOP.....778
E-3 ENGINE STOPS WHEN MACHINE IS TRAVELING.....778
E-4 TRANSMISSION DOES NOT RETURN TO NEUTRAL.....779
E-5 TRANSMISSION DOES NOT WORK NORMALLY.....780
E-6 KICK-DOWN SWITCH DOES NOT WORK.....799
E-7 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON.....801
E-8 KICK-DOWN OPERATION IS NOT CANCELED.....802
E-9 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2.....803
83 DISASSEMBLY AND ASSEMBLY....804
MACHINE MONITOR....805
REMOVAL....805
INSTALLATION....806
90 OTHER....808
93 DISASSEMBLY AND ASSEMBLY....808
CAB....809
REMOVAL....809
INSTALLATION....809
CAB....810
97 GEAR PUMP....812
GENERAL....813
PRINCIPLE OF OPERATION....814
PRESSURE LOADED TYPE GEAR PUMP....817
FIXED SIDE PLATE NPE GEAR PUMP....819
SA SERIES....820
STRUCTURE....820
TESTING AND ADJUSTING....824
DISASSEMBLY....827
ASSEMBLY....831
MAINTENANCE STANDARD....836
99 METRIC CONVERSIONS....838
Komatsu Wheel Loader WA320-LC Repair Service Manual
