Komatsu Wheel Loader GALEO WA320-L, Parallel Tool Carrier WA320PT-L Repair Service Manual

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Price: US$ 35.00

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

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