Komatsu Wheel Loader WA320PT-5L Shop Manual

CEBM013602 – WA320PT-5L S/N A39001 and up
CONTENTS
REVISION PAGES
01 GENERAL
GENERAL INFORMATION
LUBRICANTS
10 STRUCTURE AND FUNCTION
ENGINE AND DRIVE SYSTEM
HST HYDRAULIC SYSTEM
HST MOTOR (HYDRO-STATIC TRANSMISSION)
PUMP VALVES
TRANSFER
CLUTCH SOLENOID VALVE
DRIVE AXLES
LIMITED-SLIP DIFFERENTIALS
AXLE MOUNTING AND CENTER HINGE
STEERING SYSTEM
EMERGENCY STEERING
BRAKING SYSTEM
PARKING BRAKE
WORK EQUIPMENT
BASIC HYDRAULIC SYSTEM
E. C. S. S. Valve
HYDRAULIC COOLING SYSTEM
WORK EQUIPMENT CONTROL VALVE
WORK EQUIPMENT PPC VALVES
WA320-5L MECHANICAL AND WORK EQUIPMENT
WA320PT-5L MECHANICAL AND WORK EQUIPMENT
BUCKET POSITIONER, BOOM KICK-OUT AND DUMP SPEED
WORK EQUIPMENT CYLINDERS
HEATING AND AIR CONDITIONER PIPING
MACHINE MONITERING SYSTEM
MACHINE MONITOR
LIST OF ITEMS DISPLAYED ON MONITOR
HST SYSTEM ELECTRICAL CONTROLLER
KOMTRAX SYSTEM
20 TESTING, ADJUSTING AND TROUBLESHOOTING
STANDARD VALUE TABLE
SPECIAL TOOLS
ENGINE COMPONENTS
ACCELERATOR PEDAL
ADJUSTING ENGINE STOP SOLENOID
ADJUSTING ENGINE SPEED SENSOR
REFRIGERENT COMPRESSOR BELT
DIRECTIONAL LEVER
HST OIL PRESSURE
CLUTCH CONTROL PRESSURE
STEERING WHEEL
STEERING OIL PRESSURE
HYDRAULIC FAN
MEASURING BRAKE PEDAL
BRAKE PEDAL LINKAGE
MEASURING BRAKE PERFORMANCE
ACCUMULATOR CHARGE PRESSURE
BRAKE OIL PRESSURE
MEASURING WEAR OF BRAKE DISC
BLEEDING AIR FROM BRAKE CIRCUIT
PARKING BRAKE PERFORMANCE
PARKING BRAKE LINKAGE
WORK EQUIPMENT CONTROL LEVER
WORK EQUIPMENT PRESSURE
WORK EQUIPMENT PPC OIL PRESSURE
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
BUCKET POSITIONER
BOOM KICK-OUT
PROXIMITY SWITCH ACTUATION DISPLAY LAMP
PROCEDURE FOR CHECKING DIODE
SPECIAL FUNCTIONS OF MACHINE MONITOR
FLOW OF MODES AND FUNCTIONS
SETTING MACHINE MONITOR (EMMS)
REAL-TIME MONITORING ITEMS
PM CLINIC INSPECTION CHART
TROUBLESHOOTING (GENERAL)
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
TABLE FOR CONNECTOR PIN NUMBERS
T-ADAPTER TABLE
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR LAYOUT DRAWING
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING SYSTEM
ERROR CODE AND POSSIBLE CAUSE TABLE
FUSE SYSTEM CHECK
INFORMATION CONTAINED IN TESTING PROCEDURES

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
POINTS TO REMEMBER WHEN TROUBLESHOOTING
FUSE SYSTEM CHECK
INFORMATION CONTAINED IN TESTING PROCEDURES

DEFECTIVE COOLING (MECHANICAL)
DEFECTIVE HEATING (MECHANICAL)
ABNORMAL NOISE IS HEARD FROM SYSTEM (MECHANICAL)
WATER LEAKS FROM SYSTEM (MECHANICAL)
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)
METHOD OF USING TROUBLESHOOTING CHART
FAILURE CODE AND CAUSE TABLE

TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
(S-1) ENGINE STARTING PERFORMANCE IS POOR
(S-2) ENGINE HAS STARTING PROBLEMS
(S-3) ENGINE DOES NOT RUN SMOOTHLY
(S-4) ENGINE STOPS DURING OPERATIONS
(S-5) ENGINE SPEED HUNTS
(S-6) ENGINE LACKS POWER
(S-7) EXHAUST SMOKE IS BLACK
(S-8) OIL CONSUMPTION IS EXCESSIVE OR EXHAUST SMOKE IS BLUE
(S-9) OIL BECOMES CONTAMINATED QUICKLY
(S-10) FUEL CONSUMPTION IS EXCESSIVE
(S-11) OIL FOUND IN COOLANT, OR COOLANT SPURTS FROM RADIATOR
(S-12) OIL PRESSURE CAUTION LAMP LIGHTS UP
(S-13) OIL LEVEL RISES (COOLANT OR FUEL FOUND IN OIL)
(S-14) COOLANT TEMPERATURE TOO HIGH (OVERHEATING)
(S-15) ABNORMAL NOISE IS HEARD WHEN ENGINE IS RUNNUNG
(S-16) EXCESSIVE VIBRATION WHEN ENGINE IS RUNNING
30 DISASSEMBLY AND ASSEMBLY
HOW TO USE THIS MANUAL
PRECAUTIONS WHEN CARRYING OUT AN OPERATION
SPECIAL TOOL LIST
CONNECTOR REPAIR PROCEDURES
ENGINE ASSEMBLY
RADIATOR AND AFTER-COOLER
COOLING FAN AND FAN MOTOR ASSEMBLY
FUEL TANK ASSEMBLY
TRANSFER ASSEMBLY
TRANSFER ASSEMBLY OVERHAUL PROCEDURES
PARKING BRAKE ASSEMBLY
PARKING BRAKE ASSEMBLY OVERHAUL PROCEDURES
FRONT AXLE ASSEMBLY
REAR AXLE ASSEMBLY
FRONT AND REAR AXLE HOUSING OVERHAUL PROCEDURES
DIFFERENTIAL CARRIER OVERHAUL PROCEDURES
HST AND 4-GEAR PUMP ASSEMBLY
HST MOTOR 1 ASSEMBLY
HST MOTOR 2 ASSEMBLY
WORK EQUIPMENT CONTROL VALVE ASSEMBLY
TRAVEL DAMPER VALVE ASSEMBLY
HYDRAULIC TANK ASSEMBLY
HST PUMP OVERHAUL PROCEDURES
HST MOTOR OVERHAUL PROCEDURES
CYLINDERS
CYLINDER OVERHAUL PROCEDURES
WORK EQUIPMENT ASSEMBLY
OPERATOR’S CAB ASSEMBLY
OPERATOR’S CAB GLASS
CENTER HINGE PIN
REAR COUNTERWEIGHT
AIR CONDITIONER UNIT
REFRIGERENT COMPRESSOR ASSEMBLY
MONITOR PANEL
HST CONTROLLER
KOMTRAX TERMINAL ASSEMBLY
90 OTHER
HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM