‘SEBM006006 SOP Is4 VANINTOA\ IL KOMATSU aValice LoaDER WA3203 MACHINE MODEL SERIAL NUMBER WA320-3 50001 and up + This shop manual may contain attachments and optional equipment that are not avail- able in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. + WA320-3 mount the S6D108 engine. For details of the engine, see the 108 Series Engine Shop Manual. © 1997 KOMATSU. All Rights Reserved 00-1 Printed in Japan 09-97(03)00001 ®01 10 20 30 ® CONTENTS GENERAL STRUCTURE AND FUNCTION....... TESTING AND ADJUSTING . DISASSEMBLY AND ASSEMBLY MAINTENANCE STANDARD No. of page 01-1 41903u41903 ‘The affected pages are indicated by the use of the felsche ana ttoqeaned at oe oe : must be taken to these pages according to the list Leal nceationy Action required LIST OF REVISED PAGES var Paps Rover fenger [an rane Ravn [a anes Revion [van rows even 0- 2 @ 10-14 10- 52 10- 89 10-131 00- 2-2@ 10- 16 10- 53-1 @ 10-91 10-133, @ 00- 23@ 10-17 10- 54 10- 92 10-134 Sue | ou re ee nae @ o- 7 @ 10-42 10- 79 10-116 10-152, ew 1 @ 10- 46 10- 82-1 @ 10-120 10-155-1 @ 10- 8 10- 47-4 @ 10-86 @ 10-126 10-185-6 @ 10° 9 10-48 @ 10-87 @ 10-127, 10-155-7 @ 10- 10 10-49 @ 10- 87-1 @ 10-128, 10-155-8 @ 00-2-1 ®vow Poe See wan re foe [aa roe en 20-8 @ 20-103 @ 20-256 @ 20-358 © 2-9 ® 20-104 20-257 @ 20-359 @ 20-10 @ 20-108 OD 20-258 © 20-360 © ao | amo | eo | oe eo ee] ow ol ae | see eo | wm 6 | oo | nee 20-14 @ 20-109 © 20-262 © 20-365 © oe | wet | ome | seo 20-16 @ 20-111 @ 20-264 @ 20-367 @ 20-17 @ 20-112 @ 20-265 @ 20-368 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rave S620 [oan rane Re [oan ran Ren 30-210 @ 40- 23-3 @ 30.211 ® 40- 23-4 @ 30-212 40.28 @ 30-213 @ 40- 25 cue | wae ao | mse sine | ae mo | ae 30-219 @ 40- 30 a8 | 22 sg | fe 30-223 @ 40-34 @ Pen || a ma] ee se 5 | oe ae | ae ea | es ss 3 | ae See | a See | ee we 6 | ae mee | ue eae o | ie 30-236 @ ‘40-47 sao | 25 ae 8 | oie mee mmo ou ¢ mae mG ee oe ee con ee oe on ae on ae 40-21 @ 40-22 @ ae ne 00-2-4 ® u4ig03‘SAFETY SAFETY SAFETY NOTICE SAFETY NOTICE IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol iis used to mark safety precautions inthis manual. The cautions accompanying these symbols should always be followed care- fully. 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. 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 grind- ing 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, al- ways wear welding gloves, apron, hand shield, cap and other clothes suited for weld- ing work. 4. When carrying out any operation with two or more workers, always agree on the oper- ating procedure before starting. Always in- form 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. ‘Smoke only in the areas provided for smok- ing. Never smoke while working. 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. 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 warn- ing 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 ma- chine. 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PRECAUTIONS DURING WORK 11. 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 compo- nents of the oil, water or air circuits, first remove the pressure completely from the circuit. 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 hit- ting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under ii ternal pressure or under pressure from a spring, always leave two bolts in position ‘on opposite sides. Slowly release the pres- sure, 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 onto the floor, wipe it up immediately. Fuel or on the floor can cause you to slip, or can even start fires. 18. As a general rule, do not use gasoline to wash parts. In particular, use only the mum of gasoline when washing electrical parts. 00-4 19. 20. 21. 22. 23. 24, SAFETY NOTICE 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 be- ing operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 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. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tool is correctly assem- bled before taking any measurements. Take care when removing or installing the tracks of track-type machines. When removing the track, the track sepa- rates suddenly, so never let anyone stand at either end of the track.FOREWORD GENERAL 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 chapters; these chapters are further divided into the each main group of components. STRUCTURE AND FUNCTION This section explains the structure and funk an understanding of the structur 1m of each component. It serves not only to give 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.FOREWORD HOW TO READ THE SHOP MANUAL VOLUMES ‘Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volu Each issued as one ‘Attachments volum: volume to cover all models These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is neces- sary that chassis, engine, electrical and attach- ment volumes be available. 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 l Unit number (1. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 3. Additional pages: Additional pages are indi- cated by a hyphen (-) and number after the page number. File as in the example. Example: 10-4 12.203 10-41 12-2081 10-4.2}~ Added pages —19°703-2 105 12-208 00-6 HOW TO READ THE SHOP MANUAL REVISED EDITION MARK When a manual is revised, an edition mark (Q@G....) is recorded on the bottom of the pages. REVISIONS Revised pages are shown in the LIST OF RE- VISED PAGES next to the CONTENTS page. SYMBOLS So that the shop manual can be of ample prac- tical use, important safety and quality portions are marked with the following symbols. symbol | tem Remarks ‘Special safety precautions are By | Sate | necessary when performing the work. Special technical precautions __ | of other precautions for pre- Caution | serving standards are neces- sary when performing the work Weight of parts of systems. Caution necessary when se- lecting hoisting wire, or when ‘working posture is important, etc. Kg_]} Weight 9s that require special at n for the tightening torque | torque during assembly, [Tightening| Places to be coated with ad- Coat | hesives and lubricants, ete, Places where oil, water or fuel il, water] must be added, and the ca- pacity. Places where oil or water Drain | must be drained, and quan- tity to be drained. Ee |p| | Eb | +FOREWORD HOISTING INSTRUCTIONS HOISTING Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISAS- SEMBLY AND ASSEMBLY section, every part weighing 25 kg or more, is indicated clearly with the symbol + 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 caus- ing interference with the part to be re- moved. 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 ithout galvanizing) meter Allowable load kN tons 98 10 137 14 187 16 216 2.2 16 215 2.8 8 35.3 3.6 20 43.1 44 22.4 549 56 30 98.1 10.0 40 176.5 18.0 50 274.6 28.0 60. 392.2 40.0 & The allowable load value is estimated to be one-sixth or one-seventh of the break- 1g strength of the rope used. 2) Sling wire ropes from the middle portion of the hook. HOISTING INSTRUCTIONS Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can re- sult. Hooks have maximum strength at the middle portion. 100% 88% 79% 71% 41% saovoers 3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. B Binging 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 re- sult in a dangerous accident. 4) Do not sling a heavy load with ropes form- ing 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 allow- able load kN {kg} when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 kN {1000 kg} vertically, at various hanging angles. When two ropes sling a load vertically, up to 19.6 kN {2000 kg} of total weight can be suspended. This weight becomes 9.8 kN (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 39.2 kN (4000 kg) if they sling 2 19.6 kN (2000 kg} load at a lifting angle of 150°. A eno 5, ar se — 000 on ‘vce 160 000480 00-7FOREWORD COATING MATERIALS * The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly and assembly are listed below. % For coating materials not listed below, use the equivalent of products shown in thi COATING MATERIALS Category |Komatsucode| PartNo. | arty | Container Main applications, features + Used to prevent rubber gaskets, rubber LT-1A [790-128-9030 150g | Tube | cushions, and cock plug from cor + Used in places requiring an imme: effective, strong adhesive. Used for plas- Lt-18 |790-129-9050] 20.9 |Polyethyione| tics (except polyethylene, polyprophyie (2 pes.) | container | tetrafiuoroethlene and vinyl chloridel, rub- ber, metal and non-metal. + Features: Resistance to heat and chemi- Polyethylene| cals tre | 98840-00030 | 50.9 | container |+ Used for anti-oosening and sealant pur- pose for bolts and plugs. 790-129-8060 | Adhesive: + Used as adhesive or sealant for metal, lass (Sot of ache-| 1 kg and plastic. urs sive and [Hardening] Can hardening | agent: agent) | 500g Adhesives Lr-4 790-129-0040] 250g [Povethviene|+ Used as sealant for machined holes. Holte + Used as heat-resisting sealant for repair i705 [790-126-9120 759 | Tube |” ps0 ae * Quick hardening type adhesive Three bond Polyethylene|* Cure time: within 5 see. to 3 min 1735 |790-128-9140) | 50.9 ner |* Used mainly for adhesion of metals, rub- bers, plastics and woods. + Quick hardening type adhesive : *+ Quick cure type (max. strength after 30 min- Aronian |790-129-8130/ 29 |Powetnviene|” tes) + Used mainly for adhesion of rubbers, plas tics and metals. . + Features: Resistance to heat, chemicals Gass [794-129-9110] soce |Polvethviene|. Used at joint portions subject to high tem- container | peratures. + Used as adhesive or sealant for gaskets LG-1 [790-129-9010] 200g | Tube | and packing of power train case, etc. + Features: Resistance to heat + Used as sealant for flange surfaces and Gasket bolts at high temperature locations, used sealant tes |700-129-9070/ 14g can | to prevent seizure Used as sealant for heat resistance gasket for high temperature locations such as en- gine precombustion chamber, exhaust pipe, etc.FOREWORD COATING MATERIALS Category [Komatsu code] PartNo. | Q'ty | Container Main applications, features > Features: Resistance to water, ol Used as sealant for flange surface, thread, tc —|ya0-128-0020| 200g | Tube |r Also possible to use as sealant for flanges Ebert 2 with large clearance. + Used a5 sealant for mating surfaces of f- nal drive case, transmission case Used as sealant for various threads, pipe Potyethyine| joints, flanges, cae 790-129-9080/ 1 kg container |* Used as sealant for tapered plugs, elbows, nipples of hydraulic piping. + Features: Silicon based, resistance to heat, Gasket cold sealant LG | o9e40-0001| 2509 | Tube |. Used as sealant for flange surface, tread. + Used as sealant for ol pan, final drive case, ete + Features: Silicon based, quick hardening type tG-7 | 09920-00160 | 1509 | Tube |. Used as sealant for flywheel housing, in- take manifol ol an, thermostat housing, ete. Three bond Used as heat-esisting sealant for repairing we bond |75p-129-0090| 100g | Tube |° sede Used as lubricant for siding portion (to pre- Motybde- | MG | 09940-00051] 609 | Can |” vent from squeaking) um disulphide Used to prevent seizure or scuffing ofthe lubricant” | ump | 09040-00080] 200 | Tube | thread whon press fitting or shrink fiting. + Used as lubricant for linkage, bearings, ete Isye2-4001! + General purpose type Is¥G2-35011 cet fsvG24001tA | various | Various Is¥G2-160L1 ISYGA-160CNL1 Used for normal temperature, ight load Isveo4ooca d ease bearing at places in contact with water oF s [evezsooce Beating at paces in contact with wat c2.ca_|svG2400ca.a| various | Various Isve2-r60ca Isvca-teacncal Molybdenum 400 9 + Used for places with he load disulphide | SYG2-400M | (10 per |Belows type| ce inline lubrleant ase) 00-9FOREWORD STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUE STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS Use these torques for metric bolts and nuts. (Always use torque wrench). Thread diameter Width of bolt across flats mm mm 6 10 132814 1.3540.18 8 13 3143) 32403 10 v7 6627 67407 2 19 113210 11541 4 2 17419 182 16 28 27930 28.543 18 2 382139 3944 20 30 549+ 59 5616 2 32 74583 76485 24 36 9274 103 94.54 105 27 41 1320 140 135415 30 46 1720 190 175420, 33, 50 2210+ 240 225425 36 55 2750+ 290, 280430 39 60 3290+ 340 335435 Thread diameter Width of bolt across flats mm. mm Nm. kgm 6 70 7.852 1.95 OBx02 8 13 186249 19405 10 4 402+59 4.1406 2 27 82.352 7.85 84408 TIGHTENING TORQUE OF HOSE NUTS Use these torques for hose nuts. Thread diameter Width across flat Tightening torque Nominal No. mm mm Nm| kgm 02 4 19 245449 25205 03 18 24 494196 522 04 2 2 7854196 B22 05 24 32 137.3294 14z3 06 30 36 176.5294 1843 10 33 a 196.1449 2025 2 36 46 245.2 48 2545 4 2 55 294.2+49 3045, TIGHTENING TORQUE OF SPLIT FLANGE BOLTS Use these torques for split flange bolts. Thread diameter | Width across flat Tightening torque mm mm Nm kgm 10 4 657268 67207 2 a 112298 1541 16 22 27929 28.53 00-10FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE OF O-RING BOSS CONNECTOR Use these torques for O-ring boss connector Nominal No. [thread diameter | Width across flat Tightening torque mm mm. Nm kgm 02 18 343449 35405 03, 04 20 \Varies depending on| 93.1 9.8 9541 05, 06. 24 type of connector. 142.14 19.6 14522 10, 12 33 421.43 588 4326 14 2 877.1 132.3 8952135 TIGHTENING TORQUE OF O-RING BOSS CONNECTOR Use these torques for O-ring boss connector Nominal No, |_Thfead diameter | Width across flat Tightening torque mm mm. Nm| kgm. 08 8 14 7364 1.47 0.75+0.15 10 10 7 14274147 1.1520.15 12 2 19 17.644 1.96 e202 4 4 2 22.544 1.96 2340.2 16 16 24 29.4449 305 18 18 2 39.2449 4405 20 20 30 49449 5r05 24 24 32 68.6498 7st 30 30 32 107.84 14.7 M515 33 33 = 127.44 19.6 1342 36 36 36 161.9424 155425 a2 2 = 210.7294 21523 52 52 = 323.43 46.1 33445 Sealing sur TIGHTENING TORQUES OF FLARE NUT Use these torques for O-ring boss connector Thread diameter | Width across flat Tightening torque mm mm Nm kgm 4 19 245249 25205 18 24 492196 52 2 27 785+196 822 24 2 13734294 14x3 30 36 1765294 1823 33 a 196.149 205 36 46 245.2 49 2545 a2 55. 294.2: 49 3025FOREWORD STANDARD TIGHTENING TORQUE TIGHTENING TORQUE FOR 102 SERIES ENGINE (BOLT AND NUTS) Use these torques for metric bolts and nuts of 102 Series Engine. Thread diameter Tightening torque mm Nm kgm 6 10+2 41.02 + 0.20 8 res) 245 +041 10 4346 438 40.61 12 a2 785 41.22 TIGHTENING TORQUE FOR 102 SERIES ENGINE (EYE JOINTS) Use these torques for metric eye joints of 102 Series Engine. Thread diameter Tightening torque mm Nm kgm 6 B42 081 + 0.20 8 102 1.02 + 0.20 10 1242 1.22 £0.20 2 Ded 245 © 0.41 14 365 3.67 £0.51 TIGHTENING TORQUE FOR 102 SERIES ENGINE (TAPERED SCREWS) Use these torques for inches tapered screws of 102 Series Engine. Thread diameter Tightening torque inches Nm kgm 1716 324 031 £0.10 17/8 B42 081 + 0.20 4 1242 1.22 0.20 3/8 1642 153 £0.41 4/2 wis 245 + 0.41 aya 36 +5 3167 +051 1 60 +9 6.12 #082FOREWORD ELECTRIC WIRE CODE ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe. CLASSIFICATION BY THICKNESS Nominal oe —| cable 0.0. |Current rating] rpoticable circuit number | Numbor of [Bia of sand Crogs section) “"imm) ‘wl pplicable circuit 0.86 1" 0.32 0.88 24 12 | Starting, lighting, signal ete 2 26 032 2.09 3a 20 | Lighting, signal etc. 5 65 032 5.23 46 37 | Charging and signal 6 a4 0.45, 13.38 70 59 | Starting (Glow plug) 40 85 0.80 42.73 4 135 | Stenting 60 1 0.80 63.84 136 178__|_ Starting 100 27 0.80 109.1 176 230 | Starting CLASSIFICATION BY COLOR AND CODE Creu PHO eons) Charging | Ground | staring | Lighting | instrument | signal | Other Fication + Jen [Cove] w 8 8 R Y G c ™2Y [color] White | Black | Black Red Yellow | Groen Blue : Code] WR 7 Bw RW YR ew w Color| White & Red| _ — [Black & Whito|led & White |Yellow & Red|Green & White[Blue & White : Code] WB 7 By RE Ye GR LR Color|White & Black] — [Black & Yellow] Red & Black [Yalow & Biack| Groen & Red] Blue & Red 1 [aes oe]_ = BR RY YG Gy ly Color|White & Blue|__ — _| Black & Red Red & YellowVYelow & Green[Green & Yellow)Bue & Yellow : Code] WG = = RG YL 6B iB Color|White & Green| — —__ [Rea & Groen feiow & Biue|Green & Black) Blue & Black i Code] — = = RL yw Gt = Color] — 7 —___ | Red & Blue froliow & White|Green & Blue] — 00-13