Komatsu WA320-3 avance Wheel Loader Shop Manual (50001 and up) – SEBM010303

This Complete Service Repair Workshop Manual PDF Download for the Komatsu WA320-3 avance Wheel Loader (SN: 50001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.

APPLICABLE MODELS :

Komatsu WA320-3 avance Custom
Serial Numbers : 50001 and up

TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
90 OTHERS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Total Pages : 597
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : SEBM010303

This manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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COVER
CONTENTS

01 GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANT AND WATER

10 STRUCTURE AND FUNCTION
POWER TRAIN
POWER TRAIN SYSTEM
TORQUE CONVERTER, TRANSMISSION PIPING
TORQUE CONVERTER, TRANSMISSION HYDRAULIC SYSTEM DIAGRAM
TORQUE CONVERTER, TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
TORQUE CONVERTER
TORQUE CONVERTER OIL FILTER
TRANSMISSION
TRANSMISSION CONTROL VALVE
DRIVE SHAFT
AXLE
DIFFERENTIAL
FINAL DRIVE
AXLE MOUNT, CENTER HINGE PIN
STEERING PIPING
STEERING COLUMN
PRIORITY VALVE
STEERING VALVE (ORBIT-ROLL)
2-WAY RESTRICTOR VALVE
BRAKE PIPING
BRAKE HYDRAULIC CIRCUIT DIAGRAM
BRAKE VALVE
BRAKE CHARGE VALVE
ACCUMULATOR (FOR BRAKE)
BRAKE
PARKING BRAKE CONTROL
PARKING BRAKE
HYDRAULIC PIPING
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT LEVER LINKAGE
HYDRAULIC TANK
MAIN CONTROL VALVE
WORK EQUIPMENT LINKAGE
BUCKET
BUCKET POSITIONER
CAB
AIR CONDITIONER
ELECTRIC CIRCUIT DIAGRAM
ENGINE STARTING CIRCUIT
ENGINE STOP CIRCUIT
ENGINE STOP SOLENOID
PREHEATING CIRCUIT
ELECTRIC TRANSMISSION CONTROL
KICK-DOWN SWITCH
KICK-DOWN ELECTRICAL CIRCUIT DIAGRAM
TRANSMISSION CUT-OFF SWITCH
TRANSMISSION CUT-OFF FUNCTION

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL PARTS
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING EXHAUST GAS COLOR
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURING ENGINE OIL PRESSURE
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION
TESTING AND ADJUSTING ENGINE STOP SOLENOID LINKAGE
ADJUSTING ACCELERATOR ACTUATOR CABLE
TESTING AND ADJUSTING FUEL CONTROL CABLE
TESTING AND ADJUSTING TORQUE CONVERTER, TRANSMISSION OIL PRESSURE
PROCEDURE FOR MOVING MACHINE WHEN TRANSMISSION VALVE FAILS
TESTING AND ADJUSTING STEERING OIL PRESSURE
BLEEDING AIR FROM STEERING CIRCUIT
TESTING WHEEL BRAKE PERFORMANCE
TESTING DROP IN WHEEL BRAKE OIL PRESSURE
MEASURING WHEEL BRAKE DISC WEAR
BLEEDING AIR FROM WHEEL BRAKE CIRCUIT
TESTING AND ADJUSTING ACCUMULATOR CHARGE CUT-IN AND CUT-OUT PRESSURE
MEASURING PARKING BRAKE PERFORMANCE
TESTING AND ADJUSTING PARKING BRAKE CONTROL CABLE
TESTING WEAR OF PARKING BRAKE DISC
MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
BLEEDING AIR FROM WORK EQUIPMENT CIRCUIT
ADJUSTING WORK EQUIPMENT LEVER LINKAGE
ADJUSTING SAFETY LOCK LEVER
TESTING AND ADJUSTING OF BUCKET PROXIMITY SWITCH
TESTING AND ADJUSTING OF BOOM PROXIMITY SWITCH
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
CONNECTOR TYPES AND MOUNTING LOCATIONS
CONNECTOR PIN ARRANGEMENT DIAGRAM
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
S-2 ENGINE DOES NOT START
(1) ENGINE DOES NOT TURN
(2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)
(3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
S-6 ENGINE LACKS OUTPUT (NO POWER)
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)
S-13 OIL LEVEL RISES
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
ELECTRICAL CIRCUIT SYSTEM DIAGRAM
TRANSMISSION CONTROL CIRCUIT SYSTEM DIAGRAM
E-1 ENGINE DOES NOT START
a) STARTING MOTOR DOES NOT TURN WHEN STARTING SWITCH IS TURNED TO START
b) ENGINE STOP SOLENOID DOES NOT WORK
E-2 ENGINE DOES NOT STOP
E-3 PREHEATING DOES NOT WORK
E-4 TRANSMISSION DOES NOT CHANGE TO NEUTRAL WHEN PARKING BRAKE IS APPLIED (BUT TRANSMISSION CUT-OFF WORKS NORMALLY)
E-5 TRANSMISSION DOES NOT WORK NORMALLY
a) PROBLEM IN COMMON CIRCUIT FOR TRANSMISSION (ALWAYS STAYS IN 2ND)
b) PROBLEM IN H-L CIRCUIT
c) PROBLEM IN SPEED CIRCUIT
d) PROBLEM IN 4TH CIRCUIT (DOES NOT ENTER 4TH)
e) CONTACT IN H-L CIRCUIT
f) CONTACT IN SPEED CIRCUIT
g) GONTACT IN 4TH CIRCUIT (ALWAYS STAYS IN 4TH)
h) PROBLEM IN FORWARD CIRCUIT (REVERSE IS NORMAL)
i) PROBLEM IN REVERSE CIRCUIT (FORWARD IS NORMAL)
j) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE (DOES NOT TRAVEL FORWARD OR IN REVERSE)
k) CONTACT IN FORWARD CIRCUIT
l) CONTACT IN REVERSE CIRCUIT
m) PROBLEM IN COMMON CIRCUIT FOR FORWARD AND REVERSE
E-6 KICK-DOWN SWITCH DOES NOT WORK (THE REGULAR F1 TO F4 SHIFTS NORMALLY)
E-7 KICK-DOWN WORKS ONLY WHEN KICK-DOWN SWITCH IS ON (KICK-DOWN SWITCH RELAY DOES NOT HOLD IN POSITION)
E-8 KICK-DOWN IS NOT CANCELED
a) NOT CANCELED WHEN F/R LEVER IS OPERATED FROM F TO N OR R
b) NOT CANCELED WHEN SPEED LEVER IS OPERATED FROM 2 TO OTHER POSITION
E-9 KICK-DOWN SWITCH IS ACTUATED BY MISTAKE WHEN TRAVELING IN 2ND
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE)
POWER TRAIN
H-1 MACHINE DOES NOT START
H-2 TRAVEL SPEED IS SLOW, THRUSTING POWER IS WEAK, LACKS POWER ON SLOPES
H-3 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR
H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR
H-5 TORQUE CONVERTER OIL TEMPERATURE IS HIGH
STEERING SYSTEM
H-6 STEERING WHEEL DOES NOT TURN
H-7 STEERING IS HEAVY
H-8 STEERING WHEEL SHAKES OR THERE IS EXCESSIVE SHOCK
BRAKE SYSTEM
H-9 BRAKES DO NOT WORK OR BRAKING EFFECT IS POOR
H-10 BRAKES ARE NOT RELEASED OR BRAKES DRAG
WORK EQUIPMENT
H-11 BOOM DOES NOT RISE
H-12 BOOM MOVEMENT IS SLOW OR BOOM LACKS LIFTING POWER
H-13 WHEN BOOM IS RAISED, IT MOVES SLOWLY AT A CERTAIN HEIGHT
H-14 BUCKET CANNOT BE PUSHED WITH BOOM CYLINDER (BUCKET FLOATS)
H-15 EXCESSIVE HYDRAULIC DRIFT OF BOOM
H-16 BOOM SHAKES DURING OPERATION
H-17 BOOM DROPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO RAISE
H-18 BUCKET DOES NOT TILT BACK
H-19 BUCKET MOVEMENT IS SLOW OR TILT-BACK LACKS POWER
H-20 BUCKET MOVEMENT BECOMES SLOW DURING TILT-BACK OPERATION
H-21 BUCKET CANNOT BE PUSHED WITH BUCKET CYLINDER
H-22 EXCESSIVE HYDRAULIC DRIFT OF BUCKET
H-23 BUCKET SHAKES DURING LOADING OPERATION
H-24 BUCKET DUMPS MOMENTARILY WHEN CONTROL LEVER IS OPERATED FROM HOLD TO TILT
H-25 BOOM, BUCKET CONTROL LEVERS ARE HEAVY OR DO NOT MOVE SMOOTHLY

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
STARTING MOTOR
REMOVAL AND INSTALLATION
ALTERNATOR
REMOVAL AND INSTALLATION
ENGINE OIL COOLER
REMOVAL AND INSTALLATION
FUEL INJECTION PUMP
REMOVAL
INSTALLATION
WATER PUMP
REMOVAL AND INSTALLATION
TURBOCHARGER
REMOVAL AND INSTALLATION
NOZZLE HOLDER
REMOVAL
INSTALLATION
THERMOSTAT
REMOVAL AND INSTALLATION
ENGINE HOOD
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
ENGINE
REMOVAL
INSTALLATION
TORQUE CONVERTER CHARGING PUMP
REMOVAL AND INSTALLATION
TORQUE CONVERTER, TRANSMISSION
REMOVAL
INSTALLATION
TORQUE CONVERTER
DISASSEMBLY
ASSEMBLY
TRANSMISSION
DISASSEMBLY
ASSEMBLY
CLUTCH PACK
DISASSEMBLY
ASSEMBLY
PARKING BRAKE
DISASSEMBLY
ASSEMBLY
TRANSMISSION CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRANSMISSION SOLENOID VALVE
DISASSEMBLY AND ASSEMBLY
DRIVE SHAFT
DISASSEMBLY
ASSEMLBY
FRONT AXLE
REMOVAL
INSTALLATION
REAR AXLE
REMOVAL
INSTALLATION
DIFFERENTIAL
DISASSEMBLY
ASSEMBLY
AXLE HOUSING
DISASSEMBLY
ASSEMBLY
CENTER HINGE PIN
REMOVAL
INSTALLATION
STEERING VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
PRIORITY VALVE
REMOVAL AND INSTALLATION
STEERING CYLINDER
REMOVAL AND INSTALLATION
BRAKE VALVE
DISASSEMBLY
ASSEMBLY
PARKING BRAKE DISC
REMOVAL
INSTALLATION
HYDRAULIC TANK
REMOVAL AND INSTALLATION
HYDRAULIC FILTER
REMOVAL AND INSTALLATION
HYDRAULIC COOLER
REMOVAL AND INSTALLATION
HYDRAULIC STEERING PUMP
REMOVAL AND INSTALLATION
MAIN CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
BUCKET CYLINDER
REMOVAL
INSTALLATION
BOOM CYLINDER
REMOVAL
INSTALLATION
HYDRAULIC CYLINDER
DISASSEMBLY
ASSEMBLY
WORK EQUIPMENT
REMOVAL
INSTALLATION
COUNTERWEIGHT
REMOVAL AND INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
CAB
REMOVAL AND INSTALLATION
FLOOR FRAME
REMOVAL
INSTALLATION
ACCUMULATOR CHARGE VALVE
REMOVAL AND INSTALLATION
ACCUMULATOR UNIT
REMOVAL AND INSTALLATION
AIR CONDITIONER UNIT
REMOVAL
INSTALLATION
AIR CONDITIONER COMPRESSOR
REMOVAL
INSTALLATION
MONITOR PANEL
REMOVAL AND INSTALLATION

40 MAINTENANCE STANDARD
ENGINE MOUNT, TRANSMISSION MOUNT
TORQUE CONVERTER CHARGING PUMP
TORQUE CONVERTER
TRANSMISSION
TRANSMISSION CONTROL VALVE
DRIVE SHAFT
DIFFERENTIAL
FINAL DRIVE
AXLE MOUNT
CENTER HINGE PIN
STEERING COLUMN
PRIORITY VALVE
STEERING CYLINDER MOUNT
BRAKE
BRAKE VALVE
PARKING BRAKE
HYDRAULIC PUMP (SEERING, HYDRAULIC, BRAKE CHARGE PUMP)
MAIN CONTROL VALVE
HYDRAULIC CYLINDER
WORK EQUIPMENT LINKAGE
BUCKET
BUCKET POSITIONER AND BOOM KICK-OUT

90 OTHERS
ELECTRIC CIRCUIT DIAGRAM (1/2)
ELECTRIC CIRCUIT DIAGRAM (2/2)

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