Komatsu WA320-5H Wheel Loader Service Repair Shop Manual (H50051 and up) - VEBM240100

This Complete Service Repair Workshop Manual PDF Download for the WA320-5H Komatsu Wheel Loader (SN: H50051 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 WA320-5H Wheel Loader
Serial Numbers : H50051 and up


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
20 TESTING AND ADJUSTMENT
30 DISASSEMBLY AND ASSEMBLY
90 OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : VEBM240100
Total Pages : 972


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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SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
GENERAL PRECAUTIONS
PREPARATIONS FOR WORK
PRECAUTIONS DURING WORK

FOREWORD
GENERAL
STRUCTURE AND FUNCTION
TESTING AND ADJUSTING
DISASSEMBLY AND ASSEMBLY
MAINTENANCE STANDARD
OTHERS
HOW TO READ THE SHOP MANUAL
VOLUMES
DISTRIBUTION AND UPDATING
FILING METHOD
REVISED EDITION MARK
REVISIONS
SYMBOLS
HOISTING INSTRUCTIONS
HOISTING
WIRE ROPES
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Disconnection
Connection
COATING MATERIALS
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS
TIGHTENING TORQUE FOR 102 ENGINE SERIES
Tightening torque table for hoses (taper seal type and face seal type)
ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
CLASSIFICATION BY COLOR AND CODE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE
EXAMPLE
Millimeters to inches
Millimeters to Inches
Kilogram to Pound
Liter to U.S. Gallon
Liter to U.K. Gallon
kgm to ft. lb
kg/cm2 to lb/in2
Temperature
UNITS
Example:

01 GENERAL
GENERAL ASSEMBLY DRAWINGS
SPECIFICATIONS
WEIGHT TABLE
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
Engine mount and transfer mount
Damper
Outline
Cooling system
Specification
Power train
Power train system diagram
Outline
Drive shaft (propeller shaft)
Outline
HST hydraulic piping diagram
HST pump
Specifications
Operation
Flow of power
Flow of oil
High-pressure relief valve
Function
Operation
Low-pressure relief valve
Function
Operation
HST charge pump
Outline
Specifications
Function
Speed-related valve (DA valve)
Function
Operation
High-pressure cut-off valve
Function
Operation
HST motor
HST motor 1
Specifications
HST motor 2
Specifications
Principle
Structure
Operation
EP servo valve
Function
Operation
HA servo valve
Function
Operation
Forward-reverse shuttle valve
Function
Operation
Transfer
Outline
Relationship between transfer clutch and transfer clutch pressure at each gear speed
Input shaft portion
Output shaft portion
Operation of clutch
When clutch is ON (fixed)
When clutch is OFF (released)
Low-speed mode
Operation
High-speed mode
Operation
Clutch solenoid valve
Operation
Axle
FRONT AXLE
REAR AXLE
Differential
FRONT DIFFERENTIAL
REAR DIFFERENTIAL
Outline
When traveling in a straight line
When turning
Torque proportioning differential
Outline
Operation
Straight travel (When the road resistances under both tires are the same)
Travel on soft ground (When the road resistances under both tires are different)
Limited-slip differential
FRONT
Operation of limited-slip differential
Brake torque generation mechanism of left and right side gears (5).
When traveling in a straight line
When turning
Final drive
Outline
Axle mounting and center hinge pin
Outline
Steering piping
Steering column
Priority valve
Outline
Operation
Orbit-roll valve
Outline
Structure
Operation
CONNECTION BETWEEN HAND PUMP AND SLEEVE
Role of centering spring
Cushion valve
Outline
Function
Steering cylinder
Emergency steering piping
Emergency steering valve
Operation
When engine and steering pump are normal
When engine or steering pump is abnormal
Brake piping
Brake valve
Outline
Operation
When only either brake operates (When either brake fails)
Inching valve
Outline
Charge valve
Function
Operation
Accumulator (for brake)
Function
Slack adjuster
Function
Operation
When brake is applied
When brake is released
Brake
Outline
Outline
When brake is applied
When brake is released
Parking brake control
Outline
Parking brake
Outline
white 10-96
Hydraulic piping
Outline
Work equipment lever linkage
2-lever type
Multi function mono-lever type
(If equipped)
Hydraulic tank
Specifications
Breather
Prevention of negative pressure in tank
Prevention of rise of pressure in tank
4-gear pump unit
SAR(3)90 + (2)32 + SBR(1)18 + 12
Outline
Accumulator (for PPC circuit)
Outline
Specifications
Lock valve
Outline
E. C. S. S. valve
(E. C. S. S. : Electronically Controlled Suspension System)
(If equipped)
Accumulator (for?E.?C.?S.?S.)
(If equipped)
Function
Specifications
Hydraulic piping of cooling system
Outline
Cooling fan motor
Specifications
Function
Principle of operation
Work equipment control valve
1. 2-Spool valve
2. 3-spool valve
3. Relief valve
Function
Operation
4. Safety-suction valve
Function
Operation
(1) Operation as safety valve
(2) Operation as suction valve
5. Suction valve
Function
Operation
6. Cut-off valve
Function
Operating condition of cut-off valve
(1) When work equipment pump pressure is lower than cut-off pressure
(2) When work equipment pump pressure is higher than cut-off pressure
7. Operation of work equipment control valve
(1) Lift arm and bucket spool neutral position
Operation
(2) Lift arm spool raise position
Operation
(3) Lift arm spool lower position
Operation
(4) Lift arm spool float position
Operation
(5) Bucket spool dump position
Operation
(6) Bucket spool tilt position
Operation
Work equipment PPC valve
2-lever type
Operation
Mono-lever type
Operation
Attachment PPC valve
Operation
Work equipment linkage
Bucket
Bucket positioner and boom kick-out
Outline
Bucket positioner
Boom kick-out
Operation of proximity switch
When bucket is tilted
Function of proximity switch
When object of sensing is over sensing face of proximity switch
When object of sensing is apart from over sensing face of proximity switch
When lift arm is raised
Function of proximity switch
When object of sensing is over sensing face of proximity switch
When object of sensing is apart from over sensing face of proximity switch
Work equipment cylinder
LIFT CYLINDER
BUCKET CYLINDER
Air conditioner
AIR CONDITIONER PIPING
Machine monitoring system
Outline
Individual circuit diagrams of the machine monitor
Starting and lighting
Power supply and network
Speed meter specification
Load meter specification
Sensing
HST safety control
Autmatic preheating
Load meter
Load meter specification
Machine monitor
Speed meter specification
Load meter specification (If equipped)
List of items displayed on monitor
Service mode functions
Items Related to the Fault History of Electric System
Items Related to the Fault History of Machine System
Real-time monitor function Speed meter specification
Real-time monitor function Load meter specification
Real-time Monitoring Items
(Reference) Inspection with real-time monitor
Tuning function
Maintenance functions
How to input interval
Setting required when optional device is installed
Function of selecting optional device
Speed meter specification
Selection of tire deviation
Function of selecting optional device
Load meter specification
Selection of tire deviation
Selection of lift arm deviation
Selection of printer setting state
Machine serial No. setting function
Load Meter Function
Input / Ouput signal
Speed meter specification
Load meter specification
Electrical system (HST controller system)
System diagram
Control function
HST controller
Input and output signals
Function of selecting directional selector switch
(If equipped)
Outline
Function
Operation
When travel direction is changed with directional lever
When directional selector switch is selected to be used
When travel direction is changed with directional selector switch
When directional lever has priority
Engine start circuit
Function
Operation
Engine stop circuit
Operation
Preheating circuit (automatic preheating system)
Outline
Operation
Parking brake circuit
Operation
Electronically controlled suspension system
Electronically Controlled Suspension System (Abbreviation: ECSS)
(If equipped)
Function
System operation table
Sensors
Engine speed sensor
Function
Speed sensor
Function
ENGINE OIL PRESSURE SENSOR
Function
FUEL LEVEL SENSOR
Function
COOLANT TEMPERATURE SENSOR (FORMONITOR)
HST oil temperature sensor
Function
COOLANT TEMPERATURE SENSOR (FOR PREHEATING)
Function
Axle oil temperature sensor
Function
HST oil pressure sensor Oil puressure sensor for load meter (Load meter specification)
Function
Steering oil pressure sensor
(Machines equipped emergency steering)
Emergency steering oil pressure sensor
(Machines equipped emergency steering)
Function
HST filter clogging sensor
Function
COOLANT LEVEL SENSOR
Function
Engine oil level sensor
Function
Air cleaner clogging sensor
Function
Lift arm angle sensor (Load meter specification) (If equipped)
Function
STANDARD VALUE TABLE FOR engine
STANDARD VALUE TABLE FOR CHASSIS

20 TESTING AND ADJUSTING
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
Measuring, testing operating force of accelerator pedal
Adjusting engine stop solenoid
Adjusting engine speed sensor
Testing and adjusting air conditioner compressor belt tension
Measuring directional lever
Testing and adjusting HST oil pressure
Measuring clutch control pressure
Testing and adjusting steering wheel
Testing and adjusting steering oil pressure
Bleeding air from steering circuit
Testing hydraulic fan
Measuring brake pedal
Testing and adjusting brake pedal linkage
Measuring brake oil pressure
Bleeding air from brake circuit
Measuring parking brake performance
Measuring and adjusting work equipment control lever
Testing and adjusting work equipment hydraulic pressure
Testing and adjusting work equipment PPC oil pressure
Bleeding air
Releasing remaining pressure in hydraulic circuit
Testing and adjusting bucket positioner
Testing and adjusting of boom kick-out
Checking proximity switch actuation display lamp
Special functions of machine monitor
Pm CLINIC INSPECTION CHART
TESTING AND ADJUSTING
Points to remember when troubleshooting
Sequence of events in troubleshooting
Precautions when carrying out maintenance
Check before troubleshooting
Categories, procedure, and method of using troubleshooting charts
Phenomena considered to be failures and troubleshooting no.
Connection table for connector pin numbers
T-adapter table
Connector types and mounting locat
ions
Connector layout drawing
TROUBLESHOOTING
Before troubleshooting code display
Before troubleshooting electrical system
Information contained in troubuleshooting table
TROUBLESHOOTING OF HST CONTROLLER SYSTEM (HST MODE)
Before troubleshooting code display
Before troubleshooting electrical system
Information contained in troubuleshooting table
TROUBLESHOOTING OF monitor SYSTEM (mon MODE)
Before troubleshooting electrical system
Information contained in troubuleshooting table
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
Method of using troubleshooting chart
Failure code and cause table
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
Method of using troubleshooting charts
TROUBLESHOOTING OF ENGINE (S MODE)
How to read this manual
Removal and installation of assemblies
Disassembly and assembly of assemblies
Precautions when carrying out operation
Special tool list
Sketch of special tools
Removal, installation of fuel injection pump assembly
Special tools
Removal
Installation
Removal, installation of nozzle holder assembly
Special tools
Removal
Installation
Removal, installation of cylinder head assembly
Special tools
Removal
Installation
Removal, installation of engine assembly
Removal
Installation
Removal, installation of radiator assembly
Removal
Installation
Removal, installation of air aftercooler
Removal
Installation
Removal, installation of hydraulic oil cooler assembly
Removal
Installation
Removal, installation of cooling fan and fan motor assembly
Removal
Installation
Removal, installation of fuel tank assembly
Removal
Installation
Removal, installation of transfer
Removal
Installation
Disassembly, assembly of transfer assembly
Special tools
Disassembly
Assembly
Removal, installation of parking brake assembly
Removal
Installation
Disassembly, assembly of parking brake assembly
Special tools
Disassembly
Assembly
Removal, installation of front axle assembly
Removal
Installation
Removal, installation of rear axle assembly
Removal
Installation
Disassembly, assembly of axle housing assembly
Special tools
Disassembly
Assembly
Disassembly, assembly of differential assembly
Special tools
Assembly
Removal, installation of HST pump and 4-gear pump assembly
Removal
Installation
Removal, installation of HST motor 1 assembly
Removal
Installation
Removal, installation of HST motor 2 assembly
Removal
Installation
Removal, installation of work equipment control valve assembly
Removal
Installation
Removal, installation of travel damper valve assembly
Removal
Installation
Removal, installation of hydraulic tank assembly
Removal
Installation
Removal, installation of work equipment assembly
Removal
Installation
Disassembly and assembly of HST pump assembly
Special tools list
Disassembly
Assembly
Disassembly and assembly of HST motor assembly
Special tools list
Disassembly
Assembly
Disassembly, assembly of hydraulic cylinder assembly
Special tools
Disassembly
Assembly
Removal, installation of operator's cab assembly
Special tools
Removal
Installation
Removal, installation of operator's cab glass (Stuck?glass)
Special tools
Removal
Installation
Coating materials
Removal, installation of center hinge pin
Special tools
Removal
Installation
Removal, installation of counterweight
Removal
Installation
Removal, installation of air conditioner unit assembly
Special tools
Removal
Installation
Removal, installation of air conditioner compressor assembly
Special tools
Removal
Installation
Removal, installation of monitor panel
Removal
Installation

30 DISASSEMBLY AND ASSEMBLY

90 OTHERS

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