Page 1

VEBM450104

Shop Manual

WA320-3 Wheel Loader Serial Number

WA320H20051 and up

© 2000 All Rights Reserved Printed in Europe 03/2000


CONTENTS No. of page

01

GENERAL .........................................................................

01-1

10

STRUCTURE AND FUNCTION .......................................

10-1

20

TESTING AND ADJUSTING ............................................

20-1

30

DISASSEMBLY AND ASSEMBLY ...................................

30-1

40

MAINTENANCE STANDARD...........................................

40-1

00-2


SAFETY

SAFETY NOTICE

SAFETY SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. Some of the described service and repair techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol is used to mark safety precautions in this manual. The cautions accompanying these symbols must 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 Mistakes in operation are extremely dangerous. Read the OPERATION AND MAINTENANCE MANUAL carefully BEFORE operating the machine! Always follow the safety rules valid in your country carefully! 1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. • 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. 6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places.

Always keep the work area clean and make sure that there is no dirt or oil on the floor. Never smoke while working. Smoke only in the areas provided for smoking.

PREPARATIONS FOR WORK 7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving. 8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground and install the safety bar on the frame. 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.

00-3


SAFETY

SAFETY NOTICE

PRECAUTIONS DURING WORK 11. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.

17. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.

12. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.

18. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.

13. 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. 14. Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 15. 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. 16. 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.

00-4

19. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts. Do not smoke! 20. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. • When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 21. 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. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 23. 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.


F O R EW ORD

GENERAL

F O R EW OR D GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the service personnel an accurate understanding of the product and by showing them 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 chapters; these chapters are further divided into the each main group of components.

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. Use the specifications given in the book with the latest date.

00-5


F O R EW OR D

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL VOLUMES

SYMBOLS

Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:

So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Each issued as one Electrical volume: volume to cover all Attachments volume: models

}

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes are available.

Symbol

ÂŤ

Item Safety

Special safety precautions are necessary when performing the work.

Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work.

DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 - 3 Item number (10. Structure and Function) Consecutive page number for each item. Example 2 (Engine volume): 12 - 5 Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indicated by a hyphen (-) and number after the page number. File as in the example. Example: 10-4 10-4-1 10-4-2 10-5

00-6

Added pages

12-203 12-203-1 12-203-2 12-204

Remarks

Weight

Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.

Tightening Places that require special attention for the tightening torque torque during assembly. Coat

Places to be coated with adhesives and lubricants, etc.

Oil, water

Places where oil, water or fuel must be added, and the capacity.

Drain

Places where oil or water must be drained, and quantity to be drained.


F O R EW ORD

HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS HOISTING Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol

WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below: Wire ropes (Standard "Z" or "S" twist ropes without galvanizing) Rope diameter (mm)

Allowable load (tons)

10

1.0

11.2

1.4

12.5

1.6

14

2.2

16

2.8

18

3.6

20

4.4

22.4

5.6

30

10.0

40

18.0

50

28.0

60

40.0

« The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. 2) Sling wire ropes from the middle portion of the hook.

100%

88%

79%

71%

41% SAD00479

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120° hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150°.

α kg

Load capacity (kg)

• If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interference with the part to be removed.

2000

1900 1700

2000

1400 1000 1000 500

300

600

900

1200

Lifting angle (α)

1500 SAD00480

00-7


01

GENERAL

Up to SN WA320H20560: Dimensions and weights ................................. 01- 3 Specifications .................................................01- 4 Weight table ................................................... 01- 7 General view of controls and gauges ............ 01- 8 SN WA320H20561 and up: Dimensions and weights ................................. 01- 9 Specifications .................................................01-10 List of lubricant and water ............................. 01-13 Outlines of service .......................................... 01-15 General view of controls and gauges ............01-18 Torque list ....................................................01-20

01-1 


GENERAL

DIMENSIONS, WEIGHTS AND OPERATING DATA

Up to SN WA320H20560

DIMENSIONS, WEIGHTS AND OPERATING DATA

Buckets

(capacities in accordance to ISO 7546)

m3

2,6

2,9

Specific density Bucket weight w/o teeth Stat. tipping weights, straight Stat. tipping weights, articulated 40° Breakout force hydraulic Hydraulic lifting capacity, on ground Operating weight

t/m3 kg kg kg kN kN kg

1.75 1.185 11.730 10.100 129 145 13.740

1.6 1.230 11.430 9.820 124 144 13.785

a b c d e f

Reach at full lift 45° Dumping height 45° Lift height, hinge pin Bucket to edge height Digging depth Carry height, hinge pin

mm mm mm mm mm mm

1.032 2.820 3.814 5.162 58 442

1.067 2.785 3.814 5.162 58 442

A B C D E F H

Overall length Wheelbase Bucket width Width less bucket Track width Ground clearance Overall height

mm mm mm mm mm mm mm

7.257 3.030 2.740 2.598 2.050 380 3.315

7.307 3.030 2.740 2.598 2.050 380 3.315

Modified space due to:

Special buckets: 3,8 m3 - light material bucket

Additional CounterSolid weight tyres Weight Dump load 0° 45° Overall length

+ 325kg

+ 820kg

+ 865kg + 720kg

+ 1345kg + 1180kg

The 2,6/2,9 m3 standard buckets shown in the table can be supplied with bold on cutting edge.

Material

Bucket contents %

Density t/m 3

Earth Clay Sand Gravel Rock

100-115 110-120 100-110 100-110 75-100

1.5-1.6 1.5-1.7 1.4-1.8 1.5-2.0 1.6-2.0

+ 175mm

01-3


GENERAL

SPECIFICATIONS

SPECIFICATIONS Machine model

WA320-3

Serial No.

H20001 - H20560

Model Type No. of cylinders – bore x stroke Engine

Piston displacement

(mm) (cc)

Flywheel horsepower Maximum torque

124 (168)/2,350

(Nm (kgm)/rpm)

648 (66)/1,600 24 V 7.5 kW

Alternator

24 V 50 A

Battery

12 V

Torque converter Power train

8,270

(kW (PS)/rpm)

Starting motor

Axle, wheel

Cummins 6CT8.3 4-cycle, water-cooled, in-line, 6-cylinder, direct injection, with turbocharger 6 – 114 x 135

143 Ah x 2

3-element, 1-stage, single-phase (Komatsu TCA32-8A) Spur gear, constant-mesh multiple-disc, hydraulically actuated, modulation type

Transmission Reduction gear

Spiral bevel gear

Differential

Straight bevel gear, torque proportioning

Final drive

Planetary gear single stage, splash lubrication

Drive type

Front-, rear-wheel drive

Tire

20.5-25-12PR

Wheel rim

17.00 x 25-1.7 Front tire

(MPa (bar))

0.275 (2.8)

Rear tire

(MPa (bar))

0.275 (2.8) Fixed-frame semi-floating wheel

Inflation pressure

Center pin support type semi-floating wheel

Brakes

Main brake

01-4

Parking brake

Front/rear wheel independent braking wet-type sealed disc brakes with hydraulic power-doubling device Thrust shaft (transmission shaft) braking, wet-type disc brake


Steering system

GENERAL

SPECIFICATIONS

Machine model

WA320-3

Serial No.

H20001 - H20560

Type

Articulated steering

Structure

Hydrostatic

Hydraulic pump type (Hydraulic+Steering+Switch+PPC pump)

Work equipment

Control valve Cylinder

Hydraulic system

Delivery

(SAL(3)71+(3)32+(3)32+(1)20) (l/min.)

Set pressure for work equipment

165+77+77+49

(MPa (bar))

Spool type 20.59 (210)

(MPa (bar))

Orbit-roll valve type 20.59 (210)

Boom cylinder No. – bore x stroke

(mm)

Reciprocating piston 2 – 140 x 703

Bucket cylinder No. – bore x stroke

(mm)

Reciprocating piston 1 – 160 x 489

Steering cylinder No. – bore x stroke

(mm)

Reciprocating piston 2 – 70 x 460

Set pressure for steering

Link type Bucket edge type

Single link Flat edge with BOC

01-5


GENERAL

SPECIFICATIONS

Up to SN WA320H20560

SPECIFICATIONS

Bucket capacity

2,3 m3

Rated load

3.680 kg 1.

7,3 km/h

2.

11,5 km/h

3.

21,6 km/h

4.

37,0 km/h

1.

7,7 km/h

2.

12,1 km/h

3.

22,6 km/h

4.

38,8 km/h

Forward

Travel speed

Reverse

Max. Rimpull

Min. turning radius

120 kN Center of outside wheel

5.535 mm

Outside portion of chassis

6.070 mm

Weight Operatingweight

13.130 kg

Engine

Model

Cummins 6CT 8.3

Flywheel horsepower

124 kW (168 PS) /2350 min-1

Maximum torque

648 Nm/1600 min-1)

Starting motor

24 V, 7,5 kW

Alternator

24 V, 50 A

Battery

2 x 12 V 143 Ah

01-6


GENERAL

WEIGHT TABLE

WEIGHT TABLE This weight table is a guide for use when transporting or handling components.

Unit: kg Machine model

WA320-3

Machine model

WA320-3

Serial No.

H20001 and up

Serial No.

H20001 and up

Engine

730

Main control valve

75

Radiator

78

Boom cylinder (each)

108

Torque converter

42

Bucket cylinder

107

Transmission

680

Engine hood (with side panel)

165

Center drive shaft

19

Front frame

1,096

Front drive shaft

15

Rear frame

870

Rear drive shaft

8

Bucket link

35

Front axle

724

Bellcrank

230

Rear axle

714

Boom (including bushing)

852

Axle pivot

74

Bucket (with BOC)

1,230

Wheel (each)

118

Counterweight

1,180

Tire (each)

193

Fuel tank

150

Orbit-roll valve

8

Battery (each)

40

Priority valve

6

Floor, Cab assembly

670

Steering cylinder (each)

20

Cab

295

Hydraulic tank

134

Air conditioner unit

14

Hydraulic, Steering, Switch, PPC pump

44

Operator’s seat

38

01-7


GENERAL

GENERAL VIEW OF CONTROLS AND GAUGES

GENERAL VIEW OF CONTROLS AND GAUGES Up to SN WA320H20560 1 Main monitor 2 Horn switch 3 Hazard lamp switch 4 Directional lever 5 Speed control lever 6 Air conditioner panel 7 Speed control lever stopper 8 Wiper switch 9 Parking brake lever 10 Brake pedal 11 Steering column tilt lever 12 Brake pedal 13 Accelerator pedal 14 Lamp switch 15 Turn signal lever 16 Dimmer switch 17 Starting switch 18 Car radio 19 Kickdown switch 20 Gear hold position 22 Lift arm and bucket control lever 23 Cigarette lighter 24 Safety lock 25 Maintenance monitor

30 Turn signal pilot lamp 31 High beam pilot lamp 32 Centralized checking lamp 33 Engine pre-heating pilot lamp 34 Pilot lamp for front working lamp 35 Pilot lamp for rear working lamp 36 Transmission cut-off selector pilot lamp 37 Parking brake pilot lamp 38 Central warning lamp 39 Speedometer 40 Transmission shift indicator 41 ALS Electronic 42 Auto-greasing switch 43 HOLD signal 44 Emergency steering operating monitor

GENERAL VIEW

Main monitor

50 Fuel gauge 51 Engine cooling water temperature gauge 52 Torque converter oil temperature gauge

57 Service meter 58 Air cleaner clogging warning pilot lamp 59 Charge monitor 60 Brake oil pressure warning pilot lamp 61 Engine oil pressure warning lamp 62 Engine oil level warning pilot lamp 63 Engine water level warning lamp

Maintenance monitor

01-8


GENERAL

DIMENSIONS, WEIGHTS AND OPERATING DATA

SN WA320H20561 and up

DIMENSIONS, WEIGHTS AND OPERATING DATA

d a c H*

b f e

F* W A _A C T

E* D* C* Buckets

B A (capacities in accordance to ISO 7546)

m3

2,6

2,9

Specific density Bucket weight w/o teeth Stat. tipping weights, straight Stat. tipping weights, articulated 40° Breakout force hydraulic Hydraulic lifting capacity, on ground Operating weight

t/m3 kg kg kg kN kN kg

1.75 1.220 11.141 9.571 125,8 143,8 13.950

1.6 1.230 11.109 9.532 123,6 143,6 13.970

a b c d e f

Reach at full lift 45° Dumping height 45° Lift height, hinge pin Bucket to edge height Digging depth Carry height, hinge pin

mm mm mm mm mm mm

1.063 2.868 3.877 5.226 63 390

1.067 2.843 3.877 5.226 63 390

A B C D E F H

Overall length Wheelbase Bucket width Width less bucket Track width Ground clearance Overall height

mm mm mm mm mm mm mm

7.357 3.030 2.740 2.577 2.050 375 3.320

7.376 3.030 2.740 2.577 2.050 375 3.320

Special buckets: 3,8 m3 - light material bucket

The 2,6/2,9 m3 standard buckets shown in the table can be supplied with bold on cutting edge.

Material

Bucket contents %

Density t/m 3

Earth Clay Sand Gravel Rock

100-115 110-120 100-110 100-110 75-100

1.5-1.6 1.5-1.7 1.4-1.8 1.5-2.0 1.6-2.0

01-9


GENERAL

SPECIFICATIONS

SPECIFICATIONS Machine model

WA320-3

Serial No.

H20561 and up

Model Type No. of cylinders – bore x stroke Engine

Piston displacement

(mm) (cc)

Flywheel horsepower Maximum torque

(kW (PS)/rpm) (Nm/rpm)

Starting motor

124 (168) / 2,380 671 / 1,600

24 V 50 A

Battery

12 V

Torque converter Power train

8,270

24 V 7.5 kW

Alternator

Axle, wheel

S6D114E-1 / 419 4-cycle, water-cooled, in-line, 6-cylinder, direct injection, with turbocharger 6 – 114 x 135

143 Ah x 2

3-element, 1-stage, single-phase (Komatsu TCA32-8A) Spur gear, constant-mesh multiple-disc, hydraulically actuated, modulation type

Transmission Reduction gear

Spiral bevel gear

Differential

Straight bevel gear, torque proportioning

Final drive

Planetary gear single stage, splash lubrication

Drive type

Front-, rear-wheel drive

Tire

20.5-25-12PR

Wheel rim

17.00 x 25-1.7 Front tire

(bar)

(3.0)

Rear tire

(bar)

(2.5) Fixed-frame semi-floating wheel

Inflation pressure

Center pin support type semi-floating wheel

Brakes

Main brake

Parking brake

01-10

Front/rear wheel independent braking wet-type sealed disc brakes with hydraulic power-doubling device Thrust shaft (transmission shaft) braking, wet-type disc brake


Steering system

GENERAL

SPECIFICATIONS

Machine model

WA320-3

Serial No.

H20561 and up

Type

Articulated steering

Structure

Hydrostatic

Hydraulic pump type (Hydraulic+Steering+Switch+PPC pump)

Work equipment

Control valve Cylinder

Hydraulic system

Delivery

(SAL(3)71+(3)32+(3)32+(1)20) (l/min.)

Set pressure for work equipment

165+77+77+49

(MPa (bar))

Spool type 20.59 (210)

(MPa (bar))

Orbit-roll valve type 20.59 (210)

Boom cylinder No. – bore x stroke

(mm)

Reciprocating piston 2 – 140 x 703

Bucket cylinder No. – bore x stroke

(mm)

Reciprocating piston 1 – 160 x 489

Steering cylinder No. – bore x stroke

(mm)

Reciprocating piston 2 – 70 x 460

Set pressure for steering

Link type Bucket edge type

Single link (Double/Joystick as Option) Flat edge with BOC

01-11


GENERAL

SPECIFICATIONS

SN WA320H20561 and up

SPECIFICATIONS

Bucket capacity

2,6 m3

Rated load

4.680 kg 1.

7,4 km/h

2.

11,6 km/h

3.

21,9 km/h

4.

37,6 km/h

1.

7,8 km/h

2.

12,2 km/h

3.

22,8 km/h

4.

39,3 km/h

Forward

Travel speed

Reverse

Max. Rimpull

Min. turning radius

121 kN Center of outside wheel

5.535 mm

Outside portion of chassis

6.100 mm

Weight Operatingweight

13.950 kg

Engine

Model

S6D114E-1 / 419

Flywheel horsepower

124 kW (168 PS) /2380 min-1

Maximum torque

671 Nm/1500 min-1)

Starting motor

24 V, 7,5 kW

Alternator

24 V, 50 A

Battery

2 x 12 V 143 Ah

01-12


GENERAL

LIST OF LUBRICANT AND WATER

LIST OF LUBRICANT AND WATER LUBRICANTS, FUEL ETC. AND FILLING CAPACITIES WA320-3

Lubricants, fuel etc.

BI code ****)

Quality grades

Engine

Engine oil EO

EO 1540 A EO 1030 A NRS

CCMC D4 or, if not available, API CE or API CF -4 ²)

Transmission

Engine oil EO

EO 10

CCMC D4 or, if not available, API CD

Temperature ranges

-10° to 50° C -25° to 20° C -40° to 20° C

-

Viscosity ranges

SAE 15W-40 *) SAE 10W-30 SAE 05W-30

22,5 (19 **)

SAE 10W

42 (40**)

Fuchs: RENOGEAR HYDRA ZF 20W-40*) Komatsu: AXO 75 Caltex: RPM TRACTOR HYDRAULIC FLUID Chevron: TRACTOR HYDRAULIC FLUID Texaco: TDH OIL Mobil: MOBILAND SUPER UNIVERSAL

Universal transmission and hydraulic oil

NRS

or engine oil EO

EO 30

Universal transmission and hydraulic oil

NRS

Fuchs:

Hydraulic oil HYD

HYD 0530

HVLP, HVLP D

-35° to 50° C

ISO VG 46 *)

or engine oil EO

EO 10

CCMC D4 or, if not available, API CD

-35° to 40° C

SAE 10W

or hydraulic oil BIO-E-HYD

BIO-E-HYD 0530

HEES (to VDMA fluid technology)

-35° to 50° C

Cooling system

Long-life coolant with anti-frost and rust prevention SP-C

SP-C

Anti-frost and rust prevention

Fuel tank

Diesel fuel ³)

CFPP class B CFPP class D CFPP class E CFPP class F

DIN-EN 590

up to 0°C up to -10°C up to -15°C up to -20°C

Grease nipples, central lubrication

Multi-purpose grease MPG on a lithium base

MPG-A

KP2N-20

-10° to 50° C -35° to -10° C

Axles with standard locking differentials type KWA 012 W-1 KWA 012 W-2

Approx. filling capacity in litres

2x25

Axles with multi-disc locking differentials type KWA 012 W-3 KWA 012 W-4

Hydraulic system, steering, brakes

CCMC D4 or, if not available, API CD

-

SAE 30

RENOGEAR HYDRA ZF 20W-40*)

165 (116**)

ISO VG 46

30

221

NLGI 2 *) NLGI 0

Coolant NRS R134a (CFC-free) 1500 g Refrigerating machine oil NRS PAG (polyalkylglycol oil) 150 cm ³ The specified filling capacities are approximate guidelines; test specifications are binding. The selection of the viscosity class depends on the predominantly existing outside temperature. The temperature limits are to be regarded as guidelines which can be exceeded up or down for a brief period. Air conditioning

*) Works filling **) Top-up quantity ²) If no engine oil of the API CE or API CF-4 specification is available, API CC or API CD-classified engine oil can be used alternatively. The oil change intervals must be split in half in this case, however. ³) If the fuel sulphur content is between 0.5 and 1.0 %, the oil change interval must be 1/2 normal. With a sulphur content of more than 1.0 %, the oil change interval must be 1/4 normal. ****) BI codes are the "standard lubricants" for construction machinery and vehicles of the Hauptverband der Deutschen Bauindustrie e.V. (BI). The brochure "Regelschmierstoffe für Baumaschinen- und Fahrzeuge" (Standard Lubricants for Construction Machinery and Vehicles" can be obtained from bookstores or Bauverlag GmbH, Wiesbaden and Berlin, under the ISBN no. 3-7625-3102-1. U:\DTP\BA320gb\FÜLL-BI.TBL 02.97

01-13


GENERAL

• • •

LUBRICANT AND WATER

Only use original Komatsu parts for replacement. When changing or adding oil, do not use a different type of oil. Unless otherwise specified, the oil and coolant used at the time of shipment are as shown in the table below. Item

Lubricating and operating means

Engine

Engine oil: API CD, SAE 15W-40

Transmission

Engine oil: API CD, SAE 10W For machines with standard differential TPD: Axle oil: FUCHS RENOGEAR HYDRA ZF 20W-40 or AXO75

Axles ** For machines with multiple-disk limited-slip differential: Axle oil: FUCHS RENOGEAR HYDRA ZF 20W-40 Hydraulik tank

Hydraulic oil: Engine oil:

H-LP, DIN 51 524, part 2, ISO VG 46 or SAE 10 W, API classification CD

Lubricating nipple EP lubricating grease on lithium basis, NLGI 2 Fuel

ASTM D975: ASTM D975:

No. 2 No. 1 in winter (from October to March)

Radiator

Komatsu super coolant AF-ACL, mixed with 30 % water

Air conditioner

cfw free refrigerant R 134a

**)Axle oils (AXO) - The selection of the oils depends on the equipment of the axle: 1a: Standard axles TPD (without multi-disc limited-slip differential) Characteristics:

Type KWA 022 W-1, front Type KWA 022 W-2, rear These axles must be filled with the following recommended oil brands: FUCHS: KOMATSU: CALTEX: CHEVRON: TEXACO: MOBIL:

RENOGEAR HYDRA ZF 20W-40 AX0 75. RPM TRACTOR HYDRAULIC FLUID TRACTOR HYDRAULIC FLUID TDH OIL MOBILAND SUPER UNIVERSAL

For reasons of harmonization, engine oil in accordance API CD/SAE 30 may be used in the standard axle instead of axle oil. Any noises from the brakes do not affect the life. 1b: Axles with multi-disc limited-slip differential Characteristics:

Type KWA 022 W-3, front Type KWA 022 W-4, rear These must be filled with FUCHS: RENOGEAR HYDRA ZF 20W-40 The use of not recommended axle oils may cause unnormal noises from the differential.

01-14


GENERAL

OUTLINES OF SERVICE

Oil •

Oil is used in the engine and work equipment under extremely severe conditions (high temperature, high pressure), and it deteriorates with use. Always use oil that matches the grade and temperature given in the Operation and Maintenance Manual. Even if the oil is not dirty, always replace the oil after the specified interval.

Oil can be compared to blood in the human body, so always be careful when handling it to prevent any impurities (water, metal particles, dirt, etc.) from penetrating. The majority of problems with machines are caused by the entry of such impurities. Take particular care not to let any impurities penetrate when storing or adding oil.

Never mix oils of different grades or brands.

Always add the specified amount of oil. Having too much oil or too little oil may both cause problems.

If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such cases, please contact your Komatsu distributor.

When changing the oil, always replace the related filters at the same time.

We recommend to have an analysis of the oil made periodically to check the condition of the machine. Those who wish to use this service, are requested to their Komatsu distributor.

FUEL •

The fuel pump is a precision instrument; if fuel containing water or dirt is used, it cannot work properly.

Be extremely careful not to let impurities penetrate when storing or adding fuel.

Always use the fuel specified in the Operation and Maintenance Manual. Fuel may congeal depending on the temperature (particularly at low temperatures below -15 °C), so change to a fue matching this temperature.

To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the fuel tank after completing the day's work.

Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and water from the fuel tank.

If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from the circuit.

If the fuel sulphur content is between 0.5 and 1.0 %, the oil change interval must be 1/2 normal. If the fuel sulphur content is more 1.0 %, the oil change interval must be 1/4 normal.

01-15


GENERAL

OUTLINES OF SERVICE

COOLANT •

River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to the engine and radiator causing a defective heat exchange and overheating.

Do not use water that is not suitable for drinking.

When using anti-freeze, always observe the precautions given in the Operation and Maintenance Manual.

Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is shipped. This anti-freeze prevents corrosion in the cooling system. The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as it is even in hot areas.

Anti- freeze is flammable, so be extremely careful not to expose it to open flame or fire.

The proportion of anti-freeze to water differs according to the ambient temperature. For details of the mixing ratios, see "24.2.2 CLEANING THE INSIDE OF THE COOLING SYSTEM".

If the engine overheats, wait for the engine to cool before adding coolant.

If the coolant level is low, it will cause overheating and corrosion due to the air in the coolant.

GREASE •

Grease is used to prevent twisting and noise at the joints.

The nipples not included in the maintenance section are nipples for overhaul, so they need not be lubricated. If any part becomes stiff after being used for a long time, add grease.

Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe off the old grease in places where sand or dirt in the grease would cause the rotating parts to wear.

STORING OIL AND FUEL •

Keep oil and fuel indoors to prevent any water, dirt or other impurities from penetrating.

When keeping barrels for a long period, lay down the barrel on its side so that the filler port is at the side (to prevent moisture from being sucked in). If barrels have to be stored outside, cover them with a waterproof sheet or take other measures to protect them.

To prevent any change in quality during long term storage, be sure to use in the order of 'first in - first out' (use the oldest oil or fuel first).

01-16


GENERAL

OUTLINES OF SERVICE

BIODEGRADABLE HYDRAULIC OILS AND LUBRICANTS •

The use of biodegradable hydraulic oils and lubricants - on the basis of synthetic esters - for Komatsu machines is permitted. For information on the products cleared for use and best suited for your application contact our authorized service workshops.

OUTLINE OF ELECTRIC SYSTEM •

If the wiring gets wet or the insulation is damaged, the electric system leaks resulting in hazardous malfunctions of the machine.

Maintenance work at the electric system includes: (1) check fan belt tension, (2) check damage or wear to the fan belt and (3) check battery fluid level.

Never remove or disassemble any electric components installed in the machine.

Never install any electric components other than those specified by Komatsu.

Be careful to keep the electric system free of water when washing the machine or when it is raining.

When working on the seashore, carefully clean the electric system to prevent corrosion.

The optional power source must never be connected to the fuse, starter switch, or battery relay.

01-17


GENERAL

GENERAL VIEW OF CONTROLS AND GAUGES

GENERAL VIEW OF CONTROLS AND GAUGES STANDARD TYPE 1 Main monitor 2 Horn switch 3 Hazard lamp switch 4 Directional lever 5 Speed control lever 6 Speed control lever stopper 7 Wiper switch 8 Parking brake lever 9 Switch emergency drive 10 Brake pedal 11 Steering column tilt lever 12 Brake pedal 13 Accelerator pedal 14 Cigarette lighter 15 Lamp switch 16 Turn signal lever 17 Dimmer switch 18 Starting switch 19 Car radio 20 Kickdown switch 21 Gear hold position 22 Lift arm and bucket control lever 23 Lift arm for 3rd circuit 24 Safety lock 25 Switch air-conditioner 26 Maintenance monitor

SN: WA320H20561 and up

3 4 5

2

15 16

1

17

18 19 20 21 22

6 7 8 9

23 24 25 26 10

11

12

13 14 320_ m c 01

GENERAL VIEW

30

32

31

33

43

30 Turn signal pilot lamp 31 High beam pilot lamp 32 Centralized checking lamp 33 Engine pre-heating pilot lamp 34 Pilot lamp for front working lamp 35 Pilot lamp for rear working lamp 36 Transmission cut-off selector pilot lamp 37 Parking brake pilot lamp 38 Central warning lamp 39 Speedometer 40 Transmission shift indicator 41 ALS Electronic 42 Auto-greasing switch 43 HOLD signal 44 Emergency steering operating monitor 45 Work mode selector switch / SN: WA320H20855 and up 46 Autoshift transmission pilot switch / SN: WA320H20828 and up

44 34

45 WORK MODE H S Ec

35

42 MANUAL

36 46

41

40

39

38

37

470_264j

MAIN MONITOR

50 Fuel gauge 51 Engine cooling water temperature gauge 52 Torque converter oil temperature gauge 57 Service meter 58 Air cleaner clogging warning pilot lamp 59 Charge monitor 60 Brake oil pressure warning pilot lamp 61 Engine oil pressure warning lamp 62 Engine oil level warning pilot lamp 63 Engine water level warning lamp

01-18 

MAINTENANCE MONITOR


GENERAL

GENERAL VIEW OF CONTROLS AND GAUGES

GENERAL VIEW OF CONTROLS AND GAUGES WITH MULTI-FUNCTION CONTROL LEVER (if installed) 1 Main monitor 2 Horn switch 3 Hazard lamp switch 5 Speed control lever 6 Speed control lever stopper 7 Wiper switch 8 Parking brake lever 9 Switch emergency drive 10 Brake pedal 11 Steering column tilt lever 12 Brake pedal 13 Accelerator pedal 14 Cigarette lighter 15 Lamp switch 16 Turn signal lever 17 Dimmer switch 18 Starting switch 19 Car radio 20 Kickdown switch 21 Gear hold position 22 Multi-function control lever 23 Control lever for special equipment 24 Directional switch 25 Switch for air-conditioning 26 Maintenance monitor

#



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#

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$ % &

#

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$







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320_908

GENERAL VIEW

30

32

31

33

43

30 Turn signal pilot lamp 31 High beam pilot lamp 32 Centralized checking lamp 33 Engine pre-heating pilot lamp 34 Pilot lamp for front working lamp 35 Pilot lamp for rear working lamp 36 Transmission cut-off selector pilot lamp 37 Parking brake pilot lamp 38 Central warning lamp 39 Speedometer 40 Transmission shift indicator 41 ALS Electronic 42 Auto-greasing switch 43 Pilot lamp for gear hold position 44 Emergency steering operating monitor 45 Work mode selector switch / SN: WA320H20855 and up 46 Autoshift transmission pilot switch / SN: WA320H20828 and up

44 34

45 WORK MODE H S Ec

35

42 MANUAL

36 46

41

40

39

38

37

470_264j

MAIN MONITOR

50 Fuel gauge 51 Engine cooling water temperature gauge 52 Torque converter oil temperature gauge 57 Service meter 58 Air cleaner clogging warning pilot lamp 59 Charge monitor 60 Brake oil pressure warning pilot lamp 61 Engine oil pressure warning lamp 62 Engine oil level warning pilot lamp 63 Engine water level warning lamp

MAINTENANCE MONITOR

01-19 


GENERAL

TORQUE LIST

TORQUE LIST Unless otherwise specified, tighten the metric bolts and nuts to the torque shown in the table. The tightening torque is determined by the width across flats of the nut and bolt. If it is necessary to replace any nut or bolt, always use a Komatsu genuine part of the same size as the part that was replaced.

Tread diameter of the bolt (mm) (a)

Width across flat (mm) (b)

Nm

kgm

lbft

6 8 10 12 14

10 13 17 19 22

13.2 ± 1.4 31,4 ± 2,9 65,7 ± 6,8 112 ± 9,8 177 ± 19

1.35 ± 0.15 3,2 ± 0,3 6,7 ± 0,7 11,5 ± 1,0 18,0 ± 2,0

9.73 ± 1.03 23.2 ± 2.1 48.5 ± 5.0 82.6 ± 7.2 131 ± 14

16 18 20 22 24

24 27 30 32 36

279 ± 29 383 ± 39 549 ± 58 745 ± 78 927 ± 98

28.5 ± 3 39 ± 3 56 ± 6 76 ± 8 94.5 ± 10

206 ± 21 282 ± 29 405 ± 43 549 ± 58 684 ± 72

27 30 33 36 39

41 46 50 55 60

1320 ± 140 1720 ± 190 2210 ± 240 2750 ± 290 3280 ± 340

135 ± 15 175 ± 20 225 ± 25 280 ± 30 335 ± 35

973 ± 100 1270 ± 140 1630 ± 180 2030 ± 210 2420 ± 250

NOTE When tightening panels or other parts having tightening fixtures made of plastic, be careful not to use excessive tightening torque: doing so will damage the plastic parts.

01-20


10

STRUCTURE AND FUNCTION

Power train .......................................................10-3 Power train system ........................................... 10-4 Torque converter, transmission piping ..............10-6 Transmission hydraulic system diagram ........... 10-7 Torque converter ...............................................10-9 Torque converter oil filter ................................ 10-10 Transmission ................................................... 10-21 Clutch ............................................................. 10-23 Transmission control valve .............................. 10-41 Transmission solenoid valve ............................ 10-44 Pilot reducing valve ......................................... 10-45 Main relief valve .............................................. 10-46 Torque converter outlet port valve.................... 10-47 Priority valve ................................................... 10-48 Quick return valve ........................................... 10-49 Directional selector valve ................................ 10-53 H-L selector valve and range selector vlave .... 10-54 Emergency manual spool ............................... 10-56 Modulation valve .............................................. 10-57 Pilot oil filter .................................................... 10-60 Accumulator valve ........................................... 10-61 Drive shaft ...................................................... 10-81 Axle ................................................................. 10-82 Differential ...................................................... 10-84 Final drive ....................................................... 10-89 Axle mount, center hinge pin .......................... 10-90 Steering piping ............................................. 10-111 Steering column, Orbit roll ............................ 10-112 Priority valve ................................................. 10-113 Steering valve (Orbit roll) .............................. 10-117 Cushion valve................................................ 10-125 2-way restrictor valve .................................... 10-126 Emergency Steering ..................................... 10-127 Brake piping ................................................. 10-151 Brake hydraulic circuit diagram ................... 10-152 Brake valve ................................................... 10-153 Accumulator charge valve ............................. 10-158 Accumulator (for brake) ............................... 10-162 Brake pressure regulating valve .................... 10-172 Accumulator for PPC valve ........................... 10-174 Brake Accumulator unit ................................ 10-175 Brake ............................................................ 10-177 Parking brake control ................................... 10-179 Parking brake ............................................... 10-180

Parking brake valve ...................................... 10-181 Hydraulic piping ............................................ 10-201 Work equipment hydraulic circuit diagram ... 10-202 Work equipment lever linkage ....................... 10-210 Hydraulic tank ............................................... 10-211 Oil filter bypass valve .................................... 10-212 PPC valve ..................................................... 10-215 Operation of PPC relief valve ........................ 10-220 Accumulator (For PPC valve) ....................... 10-224 Main control valve up to H20343 ................... 10-225 Relief valve up to H20343 .............................. 10-229 Safety valve with suction up to H20343 ......... 10-230 Suction valve up to H20343 ........................... 10-231 Main control valve from H20344 up to H20710 ..... 10-232 Safety valve with suction: H20344 and up ....... 10-234 Anticavitation valve: H20344 and up ............. 10-235 Safety valve: H20344 and up ........................ 10-235 Main control valve: H20711 and up ............... 10-236 Operation of cut-off valve up to H20343 ........ 10-238 Work equipment valve operation ...................10-240 Hydraulic safety system up to H20710 ......... 10-246 Work equipment linkage ............................... 10-261 Bucket .......................................................... 10-263 Bucket positioner and boom kick-out ............ 10-264 Machine monitor system ............................... 10-291 Main monitor ................................................. 10-292 Maintenance monitor .................................... 10-296 Transmission auto-shift control function ........ 10-298 Transmission controler .................................. 10-303 E.C.S.S. (ALS-Electronic) ............................ 10-321 Sensors ........................................................ 10-341 Engine starting circuit ................................... 10-346 Etherstart (Option) ........................................ 10-347 Engine start/ stop/ preheating circuit ............ 10-348 Ribbon heater: H20561 and up ..................... 10-350 Electric transmission control ......................... 10-361 Kick-down / hold switch ................................ 10-364 Kick-down electric circuit diagram (Normal) . 10-365 Transmission cut-off switch........................... 10-370 Transmission cut-off function ........................ 10-371 Electric parking brake control ....................... 10-375 Air-conditioner .............................................. 10-451 Wiring diagrams ........................................... 10-601

10-1 


STRUCTURE AND FUNCTION

POWER TRAIN

POWER TRAIN

1. Transmission 2. Torque converter 3. Engine

4. Front axle 5. Front drive shaft 6. Center drive shaft

Outline • The motive force from engine (3) passes through the engine flywheel and is transmitted to torque converter (2), which is connected to the input shaft of transmission (1). • The transmission has six hydraulically actuated clutches, and these provide four speed ranges for both FORWARD and REVERSE. The transmission speed ranges are selected manually.

7. Rear drive shaft 8. Rear axle

The motive force from the output shaft of the transmission passes through center drive shaft (6), front drive shaft (5) and rear drive shaft (7), and is then transmitted to front axle (4) and rear axle (8) to drive the wheels.

10-3


STRUCTURE AND FUNCTION

POWER TRAIN SYSTEM

10-4

POWER TRAIN SYSTEM


STRUCTURE AND FUNCTION

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Front tire Final drive Wet type multiple disc brake Differential Front axle Front drive shaft Flange bearing Center drive shaft Parking brake Transmission Rear drive shaft Final drive Wet type multiple disc brake Differential Rear axle Rear tire Engine Torque converter Hydraulic, steering switch, PPC Pump Torque converter charging pump

POWER TRAIN SYSTEM

Outline • The motive force from engine (17) passes through the flywheel and is transmitted to torque converter (18). The torque converter uses oil as a medium. It converts the transmitted torque in accordance with the change in the load, and transmits the motive force to the input shaft of the transmission. In addition, the motive force of the engine passes through the pump drive gear of the torque converter, and is transmitted to hydraulic, steering switch, PPC Pump (19) and torque converter charging pump (20) to drive each pump. • Transmission (10) operates the directional spool and speed spool of the transmission valve through the solenoid valves, and actuates the six hydraulically actuated clutches to select one of the four FORWARD or REVERSE speeds. The transmission speed range is selected manually. • The output shaft of transmission (10) transmits the power to the front and rear axles. At the front, the power is transmitted to front axle (5) through center drive shaft (8), flange bearing (7), and front drive shaft (6). At the rear, the power is transmitted to rear axle (15) through rear drive shaft (11). • The motive force transmitted to front axle (5) and rear axle (15) has its speed reduced by the bevel gear and pinion gear of differentials (4) and (14), and is then transmitted to the sun gear shaft through the differential mechanism. • The motive force of the sun gear is rduced further by the planetary mechanism and is transmitted to the wheels through the axle shaft.

10-5


STRUCTURE AND FUNCTION

TORQUE CONVERTER, TRANSMISSION PIPING

TORQUE CONVERTER, TRANSMISSION PIPING

SN WA320H20561 and up

SBW00422

10

1. 2. 3. 4. 5.

Transmission Torque converter housing Radiator Transmission oil cooler inside radiator Transmission oil cooler behind radiator

10-6

6. 7. 8. 9.

Torque converter charging pump Transmission control valve Pilot oil filter Transmission oil filter SN WA320H20561 and up 10. Transmission oil cooler

32 0 _ m c0 2


STRUCTURE AND FUNCTION

TRANSMISSION HYDRAULIC SYSTEM DIAGRAM

TRANSMISSION HYDRAULIC SYSTEM DIAGRAM (Normal + Automatic)

10-7


STRUCTURE AND FUNCTION

TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM

TRANSMISSION HYDRAULIC SYSTEM DIAGRAM (Normal + Automatic)

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Transmission case Strainer Hydraulic pump Oil filter Pilot reducing valve Modulation valve Quick return valve Main relief valve Emergency manual spool Pilot oil filter Priority valve Solenoid valve Solenoid valve

10-8

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Solenoid valve (FORWARD) Solenoid valve (REVERSE) Solenoid valve (parking brake) Range selector valve H-L selector valve Directional selector valve Valve (non-operating) Accumulator 1st clutch 2nd clutch 3rd clutch 4th clutch

26. 27. 28. 29. 30. 31. 32. 33. 34.

REVERSE clutch FORWARD clutch Parking brake Torque converter Oil cooler Transmission lubrication Torque converter outlet valve Check valve Accumulator


STRUCTURE AND FUNCTION

TORQUE CONVERTER

TORQUE CONVERTER

1. 2. 3. 4. 5.

Turbine Drive case Stator Pilot Stator shaft

6. 7. 8. 9.

Housing PTO gear (drive) Pump Output shaft (Transmission input shaft)

Specifications Model: TCA32-8A Type: 3 element, 1 stage, 1 phase Stall torque ratio: 2.70:1

10-9


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Komatsu wa320 3 wheel loader service repair manual sn:wa320h20051 and up  
Komatsu wa320 3 wheel loader service repair manual sn:wa320h20051 and up  
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