KOMATSU WA320-3MC Wheel Loader Service Shop Repair Manual

CEBM003302 WA320-3MC WHEEL LOADER MACHINE MODEL SERIAL NUMBERS WA320-3MC A31001 and up This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to mak e changes or add improvements at any time without incurring any obligation to install such changes on products sol d previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision. MAY 1999 Copyright 1999 Komatsu America International Company ˇ

WA320-MC 0-2 ˇ CONTENTS 00 FORWARD ........................................... 00-1 01 GENERAL ............................................ 01-1 10 STRUCTURE AND FUNCTION ........................... 10-1 20 TESTING, ADJUSTING AND TROUBLESHOOTING .......... 20-1 30 DISASSEMBLY AND ASSEMBLY ......................... 30-1 40 MAINTENANCE STANDARD ............................. 40-1 90 OTHER .............................................. 90-1

WA320-3MC 0-3 ˇ The affected pages are indicated by using the Mark Indication Action following marks. It is requested that necessary actions be taken to these pages according to the table below. " New page to be added Add ! Page to be replaced Replace ( ) Page to be deleted Discard Pages without marks were previous additions or revise d pages. LIST OF ORIGINAL, NEW AND REVISED PAGES CEBM003301 MARK PAGE REV MARK PAGE REV MARK PAGE REV MARK PAGE REV ! 0-1 ˇ 0-2 10-17 10-77 10-137 ! 0-3 ˇ 10-18 10-78 10-138 ! 0-4 ˇ 10-19 10-79 10-139 ! 0-5 ˇ 10-20 10-80 10-140 ! 0-6 ˇ 10-21 10-81 10-141 00-1 10-23 10-83 10-143 00-2 10-24 10-84 10-144 00-3 10-25 10-85 10-145 00-4 10-26 10-86 10-146 00-5 10-27 10-87 10-147 00-6 10-28 10-88 10-148 00-7 10-29 10-89 10-149 00-8 10-30 10-90 10-150 00-9 10-31 10-91 10-151 00-10 10-32 10-92 10-152 00-11 10-33 10-93 10-153 00-12 10-34 10-94 10-154 00-13 10-35 10-95 10-155 00-14 10-36 10-96 10-156 00-15 10-37 10-97 10-157 00-16 10-38 10-98 10-158 00-17 10-39 10-99 10-159 00-18 10-40 10-100 10-160 00-19 10-41 10-101 10-161 00-20 10-42 10-102 10-162 01-1 10-44 10-104 10-164 01-2 10-45 10-105 10-165 01-3 10-46 10-106 10-166 01-4 10-47 10-107 10-167 01-5 10-48 10-108 10-168 01-6 10-49 10-109 10-169 01-7 10-50 10-110 10-170 01-8 10-51 10-111 10-171 01-9 10-52 10-112 01-10 10-53 10-113 01-11 10-54 10-114 01-12 10-55 10-115 01-13 10-56 10-116 01-14 10-57 10-117 01-15 10-58 10-118 01-16 10-59 10-119 10-1 10-61 10-121 10-2 10-62 10-122 10-3 10-63 10-123 10-4 10-64 10-124 10-5 10-65 10-125 10-6 10-66 10-126 10-7 10-67 10-127 10-8 10-68 10-128 10-9 10-69 10-129 10-10 10-70 10-130 10-11 10-71 10-131 10-12 10-72 10-132 10-13 10-73 10-133 10-14 10-74 10-134 10-15 10-75 10-135 10-16 10-76 10-136 10-22 10-82 10-142 10-43 10-103 10-163 10-60 10-120

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WA320-3MC 0-5 ˇ CEBM003301 LIST OF ORIGINAL, NEW AND REVISED PAGES MARK PAGE REV MARK PAGE REV MARK PAGE REV MARK PAGE REV " 30-25 ˇ " 30-96 ˇ " 30-153 ˇ " 30-217 ˇ " 30-26 ˇ " 30-97 ˇ " 30-154 ˇ " 30-218 ˇ " 30-27 ˇ " 30-98 ˇ " 30-155 ˇ " 30-219 ˇ " 30-28 ˇ " 30-99 ˇ " 30-156 ˇ " 30-220 ˇ " 30-29 ˇ " 30-100 ˇ " 30-157 ˇ " 30-221 ˇ " 30-30 ˇ " 30-101 ˇ " 30-158 ˇ " 30-222 ˇ " 30-31 ˇ " 30-102 ˇ " 30-159 ˇ " 30-223 ˇ " 30-32 ˇ " 30-103 ˇ " 30-160 ˇ " 30-224 ˇ " 30-33 ˇ " 30-104 ˇ " 30-161 ˇ " 30-225 ˇ " 30-34 ˇ " 30-105 ˇ " 30-162 ˇ " 30-226 ˇ " 30-35 ˇ " 30-106 ˇ " 30-163 ˇ " 30-227 ˇ " 30-36 ˇ " 30-107 ˇ " 30-164 ˇ " 30-228 ˇ " 30-37 ˇ " 30-108 ˇ " 30-165 ˇ " 30-38 ˇ " 30-109 ˇ " 30-166 ˇ 40-1 " 30-39 ˇ " 30-110 ˇ " 30-167 ˇ 40-2 " 30-40 ˇ " 30-111 ˇ " 30-168 ˇ 40-3 " 30-41 ˇ " 30-112 ˇ " 30-169 ˇ 40-4 " 30-42 ˇ " 30-113 ˇ " 30-170 ˇ 40-5 " 30-43 ˇ " 30-114 ˇ " 30-171 ˇ 40-6 " 30-44 ˇ " 30-115 ˇ " 30-172 ˇ 40-7 " 30-45 ˇ " 30-116 ˇ " 30-173 ˇ 40-8 " 30-46 ˇ " 30-117 ˇ " 30-174 ˇ 40-9 " 30-47 ˇ " 30-118 ˇ " 30-175 ˇ 40-10 " 30-48 ˇ " 30-119 ˇ " 30-176 ˇ 40-11 " 30-49 ˇ " 30-120 ˇ " 30-177 ˇ 40-12 " 30-50 ˇ " 30-121 ˇ " 30-178 ˇ 40-13 " 30-51 ˇ " 30-122 ˇ " 30-179 ˇ 40-14 " 30-52 ˇ " 30-123 ˇ " 30-180 ˇ 40-15 " 30-53 ˇ " 30-124 ˇ " 30-181 ˇ 40-16 " 30-54 ˇ " 30-125 ˇ " 30-182 ˇ 40-17 " 30-55 ˇ " 30-126 ˇ " 30-183 ˇ 40-18 " 30-56 ˇ " 30-127 ˇ " 30-184 ˇ 40-19 " 30-57 ˇ " 30-128 ˇ " 30-185 ˇ 40-20 " 30-58 ˇ " 30-129 ˇ " 30-186 ˇ 40-21 " 30-59 ˇ " 30-130 ˇ " 30-187 ˇ 40-22 " 30-60 ˇ " 30-131 ˇ " 30-188 ˇ 40-23 " 30-61 ˇ " 30-132 ˇ " 30-189 ˇ 40-24 " 30-62 ˇ " 30-133 ˇ " 30-190 ˇ 40-25 " 30-63 ˇ " 30-134 ˇ " 30-191 ˇ 40-26 " 30-64 ˇ " 30-135 ˇ " 30-192 ˇ 40-27 " 30-65 ˇ " 30-136 ˇ " 30-193 ˇ 40-28 " 30-66 ˇ " 30-137 ˇ " 30-194 ˇ 40-29 " 30-67 ˇ " 30-138 ˇ " 30-195 ˇ 40-30 " 30-68 ˇ " 30-139 ˇ " 30-196 ˇ 40-31 " 30-69 ˇ " 30-140 ˇ " 30-197 ˇ 40-32 " 30-70 ˇ " 30-141 ˇ " 30-198 ˇ 40-33 " 30-71 ˇ " 30-142 ˇ " 30-199 ˇ 40-34 " 30-72 ˇ " 30-143 ˇ " 30-200 ˇ 40-35 " 30-73 ˇ " 30-144 ˇ " 30-201 ˇ 40-36 " 30-74 ˇ " 30-145 ˇ " 30-202 ˇ 40-37 " 30-75 ˇ " 30-146 ˇ " 30-203 ˇ 40-38 " 30-76 ˇ " 30-147 ˇ " 30-204 ˇ 40-39 " 30-77 ˇ " 30-148 ˇ " 30-205 ˇ 40-40 " 30-78 ˇ " 30-149 ˇ " 30-206 ˇ 40-41 " 30-79 ˇ " 30-150 ˇ " 30-207 ˇ 40-42 " 30-80 ˇ " 30-151 ˇ " 30-208 ˇ 40-43 " 30-81 ˇ " 30-152 ˇ " 30-209 ˇ 40-44 " 30-82 ˇ " 30-210 ˇ 40-45 " 30-83 ˇ " 30-211 ˇ 40-46 " 30-84 ˇ " 30-212 ˇ 40-47 " 30-85 ˇ " 30-213 ˇ 40-48 " 30-86 ˇ " 30-214 ˇ 40-49 " 30-87 ˇ " 30-215 ˇ 40-50 " 30-88 ˇ " 30-216 ˇ " 30-89 ˇ " 30-90 ˇ " 30-91 ˇ " 30-92 ˇ " 30-93 ˇ " 30-94 ˇ " 30-95 ˇ

PRODUCT PUBLICATIONS INFORMATION VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION EQUIPMENT OWNERS, INCLUDING OPERATION AND MAINTENANCE MANUALS, PARTS BOOKS AND SHOP MANUALS. SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SERVIC E MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & SERVICE MANUALS IN FOREIG N LANGUAGES. THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S). DESCRIPTION FORM NUMBER PARTS BOOK - PAPER: Chassis and Engine ..................................................... BEPB005400 PARTS BOOK - MICROFICHE: Chassis and Engine ..................................................... BEPB005400 OPERATION AND MAINTENANCE MANUAL: Chassis and Engine ..................................................... CEAM003500 SHOP MANUAL: Chassis .............................................................. CEBM003302 Engine ............................................................... CEBM000601 STANDARD MAN-HOUR GUIDE : Chassis .............................................................. Engine ............................................................... SAFETY MANUAL .......................................................... WLT70-1 PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS, USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INVENTORY PROCESSING SYSTE M (PIPS). IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWIN G REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CA N BE USED. FORM KDC91D IS SHOWN ON THE REVERSE SIDE OF THIS PAGE. PUBINFOK.WPT 121297

PURCHASE ORDER NO. ORDER DATE REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS COMPLETE FORM AND RETURN TO  Komatsu America International Company 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887 COMPANY NAME ATTN. STREET ADDRESS CITY, STATE, ZIP CODE COUNTRY SHIP TO  TYPE or PRINT ONLY  PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHIN E SERIAL NUMBER MUST BE SHOWN. QTY. PUBLICATION FORM NO. P-Paper MODEL NUMBER SERIAL NUMBER PARTS BOOK M-Microfiche PUBLICATION DESCRIPTION KDC91D 081696 CURRENT PRICES WILL BE CHARGED

SAFETY SAFETY NOTICE WA320-3MC 00-5 SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep tools Mistakes in operation are extremely dangerous. Read the parts in their correct places. Always keep the work OPERATION & MAINTENANCE MANUAL carefully area clean and make sure that there is no dirt or oil BEFORE operating the machine. on the floor. Smoke only in the areas provided for 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to PREPARATIONS FOR WORK the machine. 2. When carrying out any operation, always wear safety machine on hard, level ground, and block the shoes and helmet. Do not wear loose work clothes, wheels or tracks to prevent the machine from or clothes with buttons missing. moving. ! Always wear safety glasses when hitting parts with a hammer. ! Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them. and removed parts. Always keep the tools and smoking. Never smoke while working. 7. Before adding oil or making repairs, park the 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

SAFETY SAFETY NOTICE WA320-3MC 00-6 PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or 18. As a general rule, do not use gasoline to wash hydraulic pressure measuring plugs, loosen them parts. In particular, use only the minimum of slowly to prevent the oil from spurting out. Before gasoline when washing electrical parts. disconnecting or removing components of the oil, water or air circuits, first remove the pressure 19. Be sure to assemble all parts again in their original completely from the circuit. places. Replace any damaged part with new parts. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits. 13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires. 17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. ! When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. 24. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.

FOREWORD GENERAL WA320-3MC 00-7 FOREWORD GENERAL This shop 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 shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" to "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.

KOMATSU WA320-3MC Wheel Loader Service Shop Repair Manual

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