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KOMATSU WA320-6 WA320PZ-6 SHOP MANUAL VEBM620100 – PDF DOWNLOAD
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Description
KOMATSU WA320-6 WA320PZ-6 SHOP MANUAL VEBM620100 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU WA320-6 WA320PZ-6 SHOP MANUAL VEBM620100 – PDF DOWNLOAD
Language : English
Pages : 1269
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU WA320-6 WA320PZ-6 SHOP MANUAL VEBM620100 – PDF DOWNLOAD
VEBM620100............................................................................................................................ 1 00 Index and foreword................................................................................................................. 3 100 Index......................................................................................................................... 3 Composition of shop manual.................................................................................................... 4 Table of contents............................................................................................................. 6 200 Foreword and general information.............................................................................................. 15 Safety notice................................................................................................................. 16 How to read the shop manual................................................................................................... 21 Explanation of terms for maintenance standard................................................................................. 23 Handling of electric equipment and hydraulic component........................................................................ 25 Handling of connectors newly used for engines................................................................................. 34 How to read electric wire code................................................................................................ 37 Precautions when carrying out operation....................................................................................... 40 Method of disassembling and connecting push-pull type coupler................................................................. 43 Standard tightening torque table.............................................................................................. 46 Conversion table.............................................................................................................. 50 01 Specification...................................................................................................................... 55 100 Specification and technical data.............................................................................................. 55 Specification dimension drawing............................................................................................... 57 Specifications................................................................................................................ 58 Weight table.................................................................................................................. 63 Table of fuel, coolant and lubricants......................................................................................... 65 10 Structure, function and maintenance standard....................................................................................... 67 100 Engine and cooling system..................................................................................................... 67 Engine mount and transfer mount............................................................................................... 68 Damper........................................................................................................................ 69 Cooling system................................................................................................................ 70 Cooling system hydraulic piping diagram....................................................................................... 71 Cooling fan motor............................................................................................................. 73 200 Power train................................................................................................................... 81 Power train................................................................................................................... 83 Power train system diagram.................................................................................................... 84 Drive shaft................................................................................................................... 86 HST hydraulic piping diagram.................................................................................................. 87 HST pump...................................................................................................................... 88 HST motor..................................................................................................................... 96 Transfer...................................................................................................................... 102 Clutch solenoid valve......................................................................................................... 113 Axle.......................................................................................................................... 114 Differential.................................................................................................................. 116 Torque proportioning differential............................................................................................. 121 Limited slip differential..................................................................................................... 124 Final drive................................................................................................................... 128 300 Steering system............................................................................................................... 133 Steering piping diagram....................................................................................................... 135 Steering column............................................................................................................... 136 Priority valve................................................................................................................ 137 Orbit-roll valve.............................................................................................................. 140 Cushion valve................................................................................................................. 148 Steering cylinder............................................................................................................. 149 Emergency steering piping diagram............................................................................................. 151 Emergency steering valve...................................................................................................... 152 Steering relief valve......................................................................................................... 155 400 Brake system.................................................................................................................. 157 Brake piping diagram.......................................................................................................... 159 Charge valve.................................................................................................................. 160 Brake valve................................................................................................................... 164 Inching valve................................................................................................................. 168 Accumulator (for brake)....................................................................................................... 169 Slack adjuster................................................................................................................ 170 Brake......................................................................................................................... 172 Parking brake control......................................................................................................... 177 Parking brake................................................................................................................. 178 500 Undercarriage and frame....................................................................................................... 179 Axle mount and center hinge pin............................................................................................... 180 Tires......................................................................................................................... 185 600 Hydraulic system.............................................................................................................. 187 Work equipment hydraulic piping diagram....................................................................................... 188 Work equipment control lever linkage.......................................................................................... 192 Hydraulic tank................................................................................................................ 196 4-gear pump................................................................................................................... 198 Work equipment control valve.................................................................................................. 200 Cut-off valve................................................................................................................. 226 PPC valve..................................................................................................................... 229 Lock valve.................................................................................................................... 243 Accumulator (for PPC circuit)................................................................................................. 244 Quick coupler solenoid valve.................................................................................................. 245 ECSS valve.................................................................................................................... 246 Accumulator (for ECSS)........................................................................................................ 248 700 Work equipment................................................................................................................ 249 Work equipment linkage........................................................................................................ 250 Bucket........................................................................................................................ 254 Bucket positioner and boom kick-out........................................................................................... 258 Work equipment cylinder....................................................................................................... 270 800 Cab and its attachments....................................................................................................... 273 Cab........................................................................................................................... 275 Air conditioner............................................................................................................... 276 910 Electrical system, Part 1..................................................................................................... 289 Machine monitor system........................................................................................................ 290 Machine monitor............................................................................................................... 294 920 Electrical system, Part 2..................................................................................................... 315 Electrical system (HST controller system)..................................................................................... 316 HST controller................................................................................................................ 332 ECSS system................................................................................................................... 334 KOMTRAX system................................................................................................................ 336 Engine starting circuit....................................................................................................... 338 Engine stopping circuit....................................................................................................... 340 Preheating circuit............................................................................................................ 341 Engine output derating function............................................................................................... 342 Automatic warm-up function.................................................................................................... 342 Parking brake circuit......................................................................................................... 344 Coupler plunger control system................................................................................................ 346 Max. traction switch.......................................................................................................... 347 Multi-function knob........................................................................................................... 348 Sensor........................................................................................................................ 349 20 Standard value table............................................................................................................... 357 100 Standard service value table.................................................................................................. 357 Standard service value table for engine....................................................................................... 358 Standard service value table for chassis...................................................................................... 359 30 Testing and adjusting.............................................................................................................. 365 110 Testing and adjusting, Part 1................................................................................................. 365 Tools for testing, adjusting, and troubleshooting............................................................................. 367 Measuring engine speed........................................................................................................ 372 Measuring exhaust gas color................................................................................................... 374 Adjusting valve clearance..................................................................................................... 376 Measuring compression pressure................................................................................................ 378 Measuring blow-by pressure.................................................................................................... 381 Measuring engine oil pressure................................................................................................. 382 Measuring intake air (boost) pressure......................................................................................... 383 Handling fuel system equipment................................................................................................ 385 Releasing residual pressure in fuel system.................................................................................... 385 Measuring fuel pressure....................................................................................................... 386 Measuring fuel return rate and leakage........................................................................................ 388 Bleeding air from fuel circuit................................................................................................ 392 Checking leakage in fuel system............................................................................................... 393 Handling cylinder cut-out mode operation...................................................................................... 394 Handling no-injection cranking operation...................................................................................... 394 Handling controller voltage circuit........................................................................................... 395 Check of muffler and muffler stack for looseness and damage................................................................... 395 Check of muffler function..................................................................................................... 396 Check of installed condition of cylinder head and manifolds................................................................... 396 Check of engine piping for damage and looseness............................................................................... 397 Testing and adjusting air conditioner compressor belt tension................................................................. 397 Replacing alternator belt..................................................................................................... 398 120 Testing and adjusting, Part 2................................................................................................. 399 Checking operating force of accelerator pedal................................................................................. 401 Checking directional lever.................................................................................................... 402 Testing and adjusting HST oil pressure........................................................................................ 403 Testing clutch control pressure............................................................................................... 407 Testing and adjusting steering wheel.......................................................................................... 408 Testing and adjusting steering oil pressure................................................................................... 410 Bleeding air from steering circuit............................................................................................ 412 Testing hydraulic fan......................................................................................................... 413 Measuring brake pedal......................................................................................................... 415 Testing and adjusting brake pedal linkage..................................................................................... 416 Measuring brake performance................................................................................................... 417 Testing and adjusting accumulator charge pressure............................................................................. 418 Testing wheel brake oil pressure.............................................................................................. 420 Testing wear of brake disc.................................................................................................... 423 Bleeding air from wheel brake circuit......................................................................................... 424 Releasing residual pressure in brake accumulator circuit...................................................................... 425 Testing parking brake performance............................................................................................. 426 Testing and adjusting parking brake control cable............................................................................. 427 Measuring and adjusting work equipment control lever.......................................................................... 428 Testing and adjusting work equipment hydraulic pressure....................................................................... 429 Testing work equipment PPC oil pressure....................................................................................... 430 Bleeding air from hydraulic circuit........................................................................................... 432 Releasing remaining pressure in hydraulic circuit............................................................................. 433 Testing and adjusting bucket positioner....................................................................................... 434 Testing and adjusting of boom kick-out switch................................................................................. 435 Checking proximity switch operation pilot lamp................................................................................ 436 Procedure for testing diodes.................................................................................................. 437 Preparation work for troubleshooting for electric system...................................................................... 438 Starting KOMTRAX terminal operations.......................................................................................... 442 Indicator lamps of KOMTRAX terminal........................................................................................... 446 130 Testing and adjusting, Part 3................................................................................................. 449 Adjusting machine monitor..................................................................................................... 450 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor........................................ 451 Special functions of machine monitor (EMMS)................................................................................... 453 Pm clinic inspection chart.................................................................................................... 506 40 Troubleshooting.................................................................................................................... 509 100 Failure code table and fuse locations......................................................................................... 509 Failure codes table........................................................................................................... 510 Fuse locations................................................................................................................ 516 200 General information on troubleshooting........................................................................................ 519 Points to remember when troubleshooting....................................................................................... 520 Sequence of events in troubleshooting......................................................................................... 521 Testing before troubleshooting................................................................................................ 522 Classification and procedures of troubleshooting.............................................................................. 523 Information contained in troubleshooting table................................................................................ 526 Connection table for connector pin numbers.................................................................................... 528 T- branch box and T- branch adapter table..................................................................................... 564 310 Troubleshooting by failure code (Display of code), Part 1..................................................................... 567 Failure code [2G40ZG] Brake: Oil pressure reduction........................................................................... 568 Failure code [6091NX] HST filter: Clogging.................................................................................... 570 Failure code [989FN1] Travel speed: Overrun alarm............................................................................. 571 Failure code [AA1ANX] Air cleaner: Clogging................................................................................... 572 Failure code [AB00L6] Alternator R system: Hot short.......................................................................... 574 Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/ Low charge voltage..................................... 576 Failure code [B@BAZG] Engine: Oil pressure reduction.......................................................................... 578 Failure code [B@BAZK] Engine oil: Low level................................................................................... 579 Failure code [B@BCNS] Engine: Overheat........................................................................................ 580 Failure code [B@BCZK] Engine: Low coolant level............................................................................... 582 Failure code [B@C6NS] Front brake: High oil temperature....................................................................... 584 Failure code [B@CRNS] HST: High oil temperature............................................................................... 585 320 Troubleshooting by failure code (Display of code), Part 2..................................................................... 587 Failure code [CA111] Abnormality in engine controller......................................................................... 589 Failure code [CA115] Engine Ne or Bkup speed sensor error..................................................................... 590 Failure code [CA122] Charge pressure sensor high error........................................................................ 592 Failure code [CA123] Charge pressure sensor low error......................................................................... 594 Failure code [CA131] Throttle sensor high error............................................................................... 596 Failure code [CA132] Throttle sensor low error................................................................................ 598 Failure code [CA144] Coolant sensor high error................................................................................ 600 Failure code [CA145] Coolant sensor low error................................................................................. 602 Failure code [CA153] Charge temperature sensor high error..................................................................... 604 Failure code [CA154] Charge temperature sensor low error...................................................................... 606 Failure code [CA155] Derating of speed by abnormally high charge temperature.................................................. 608 Failure code [CA187] Sensor power supply 2 low error.......................................................................... 610 Failure code [CA221] Atmospheric pressure sensor high error................................................................... 612 Failure code [CA222] Atmospheric sensor low error............................................................................. 614 Failure code [CA227] Sensor power supply 2 high error......................................................................... 616 Failure code [CA234] Engine overspeed......................................................................................... 617 Failure code [CA238] Ne speed sensor power supply error....................................................................... 618 Failure code [CA271] IMV (IMA) Short circuit.................................................................................. 619 Failure code [CA272] IMV (IMA) Disconnection.................................................................................. 620 Failure code [CA322] Injector #1 open/short error............................................................................. 622 Failure code [CA323] Injector #5 open/short error............................................................................. 624 Failure code [CA324] Injector #3 open/short error............................................................................. 626 Failure code [CA325] Injector #6 open/short error............................................................................. 628 Failure code [CA331] Injector #2 open/short error............................................................................. 630 Failure code [CA332] Injector #4 open/short error............................................................................. 632 Failure code [CA342] Calibration code inconsistency........................................................................... 634 Failure code [CA351] Injectors drive circuit error............................................................................ 636 Failure code [CA352] Sensor power supply 1 low error.......................................................................... 638 Failure code [CA386] Sensor power supply 1 high error......................................................................... 640 330 Troubleshooting by failure code (Display of code), Part 3..................................................................... 641 Failure code [CA428] Abnormally high level in water sensor.................................................................... 644 Failure code [CA429] Abnormally low level in water sensor..................................................................... 646 Failure code [CA431] Idle validation switch error............................................................................. 648 Failure code [CA432] Idle validation action error............................................................................. 652 Failure code [CA435] Engine oil pressure switch error......................................................................... 656 Failure code [CA441] Battery voltage low error................................................................................ 657 Failure code [CA442] Battery voltage high error............................................................................... 660 Failure code [CA449] Common rail pressure high error 2........................................................................ 662 Failure code [CA451] Common rail pressure sensor high error................................................................... 664 Failure code [CA452] Common rail pressure sensor low error.................................................................... 666 Failure code [CA488] Derating of torque by abnormally high charge temperature................................................. 668 Failure code [CA553] Common rail pressure high error 1........................................................................ 669 Failure code [CA559] Supply pump pressure very low error...................................................................... 670 Failure code [CA689] Engine Ne speed sensor error............................................................................. 672 Failure code [CA731] Engine Bkup speed sensor phase error..................................................................... 674 Failure code [CA757] All continuous data lost error........................................................................... 675 Failure code [CA778] Engine Bkup speed sensor error........................................................................... 678 Failure code [CA1633] KOMNET datalink timeout error........................................................................... 680 Failure code [CA2185] Throttle sensor supply voltage high error............................................................... 684 Failure code [CA2186] Throttle sensor power supply low error.................................................................. 686 Failure code [CA2249] Supply pump pressure very low error 2................................................................... 688 Failure code [CA2311] Abnormality in IMV (IMA) solenoid....................................................................... 690 Failure code [CA2555] Intake heater relay disconnection error................................................................. 692 Failure code [CA2556] Intake heater relay short circuit error................................................................. 694 340 Troubleshooting by failure code (Display of code), Part 4..................................................................... 697 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short............................................................ 698 Failure code [D192KY] ECSS solenoid relay: Hot short.......................................................................... 700 Failure code [D1B0KA] HST safety relay: Disconnection......................................................................... 702 Failure code [D1B0KB] HST safety relay: Ground fault.......................................................................... 704 Failure code [D1B0KY] HST safety relay: Hot short............................................................................. 706 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection................................................................ 708 Failure code [DAF3KK] UNSW power supply: Ground fault/ Disconnection.......................................................... 710 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection........................................................... 712 Failure code [DAJ0KK] HST controller power supply: Low voltage................................................................ 716 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality............................................................. 718 Failure code [DAJ1L4] HST controller main power line: Disconnection/ Ground fault............................................. 720 Failure code [DAJ1L6] HST controller main power line: Hot short............................................................... 722 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage........................................................... 724 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness.............................. 726 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault............................... 728 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range............................................................. 730 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals................................. 732 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection............................................................ 733 Failure code [DAJRMA] HST controller: Disagreement in option selection........................................................ 739 350 Troubleshooting by failure code (Display of code), Part 5..................................................................... 741 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line................................................. 742 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality........................................................ 748 Failure code [DD1NLD] Fan reverse switch signal: Abnormality.................................................................. 750 Failure code [DDB6KA] Parking brake reminder signal: Disconnection/ Hot short................................................. 752 Failure code [DDB6KB] Parking brake indicator signal: Ground fault............................................................ 754 Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble.... 756 Failure code [DDB6L0] Parking brake reminder signal: Ground fault............................................................. 758 Failure code [DDB6L4] Parking brake indicator signal: Disconnection/ Hot short................................................ 760 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/ Ground fault........................................... 762 Failure code [DDD7KY] Travel speed control dial signal: Hot short............................................................. 764 Failure code [DDE5MA] Emergency steering operation switch: Disconnection...................................................... 766 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault................................................................... 768 Failure code [DDK6KY] FNR lever: Hot short.................................................................................... 772 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)............................................ 774 360 Troubleshooting by failure code (Display of code), Part 6..................................................................... 777 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault.......................................... 778 Failure code [DF10KB] Travel speed range selector switch: Hot short........................................................... 782 Failure code [DGH1KX] HST oil temperature sensor: Ground fault................................................................ 784 Failure code [DGR2KB] Brake oil temperature sensor: Ground fault.............................................................. 785 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/ Hot short.................................................. 786 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault..................................................... 788 Failure code [DHH1KY] HST oil pressure sensor: Hot short...................................................................... 790 Failure code [DHTCL6] HST filter clogging sensor: Functional defect........................................................... 792 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short.............................................................. 794 Failure code [DLT3KX] Travel speed sensor B: Abnormality...................................................................... 796 Failure code [DLT4KX] Travel speed sensor A: Abnormality...................................................................... 800 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality.................................................................. 802 Failure code [DV00KY] Alarm buzzer: Hot short................................................................................. 804 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault............................................................ 806 Failure code [DW26KY] Motor 2 solenoid: Hot short............................................................................. 808 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short................................................................. 810 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/ Ground fault............................................... 812 370 Troubleshooting by failure code (Display of code), Part 7..................................................................... 815 Failure code [DX16KA] Fan EPC solenoid: Disconnection......................................................................... 816 Failure code [DX16KB] Fan EPC solenoid: Ground fault.......................................................................... 817 Failure code [DX16KY] Fan EPC solenoid: Hot short............................................................................. 818 Failure code [DX19KA] Motor 1 solenoid: Disconnection......................................................................... 820 Failure code [DX19KB] Motor 1 solenoid: Ground fault.......................................................................... 822 Failure code [DX19KY] Motor 1 solenoid: Hot short............................................................................. 824 Failure code [DX20KA] Clutch EPC solenoid: Disconnection...................................................................... 826 Failure code [DX20KB] Clutch EPC solenoid: Ground fault....................................................................... 828 Failure code [DX20KY] Clutch EPC solenoid: Hot short.......................................................................... 830 Failure code [DXH7KB] Reverse solenoid: Ground fault.......................................................................... 832 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short............................................................... 834 Failure code [DXH8KB] Forward solenoid: Ground fault.......................................................................... 836 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short............................................................... 838 Failure code [J141N1] Steering pump: Overrun alarm............................................................................ 840 Failure code [M100N1] HST pump: Overrun alarm................................................................................. 840 Failure code [M400N1] Motor 1: Overrun alarm.................................................................................. 841 400 Troubleshooting of electrical system (E-mode)................................................................................. 843 E-1 Engine does not start..................................................................................................... 845 E-2 Preheater does not operate normally....................................................................................... 852 E-3 Travel speed is low or high............................................................................................... 856 E-4 ECSS does not operate..................................................................................................... 862 E-5 ECSS keeps operating...................................................................................................... 865 E-6 Defective boom kick-out function and cancellation......................................................................... 868 E-7 Defective bucket positioner function and cancellation..................................................................... 872 E-8 Defective lift arm FLOATING holding function and cancellation............................................................. 876 E-9 Travel direction selection system does not function....................................................................... 880 E-10 Fan does not reverse..................................................................................................... 884 E-11 Fan keeps rotating in reverse............................................................................................ 888 E-12 Wiper does not operate................................................................................................... 890 E-13 Windshield washer does not operate....................................................................................... 894 E-14 Headlamp, clearance lamp and tail lamp do not light up or go off......................................................... 898 E-15 Working lamp does not light up or go off................................................................................. 906 E-16 Turn signal lamp and hazard lamp do not light up or go off............................................................... 912 E-17 Brake lamp does not light or it keeps lighting up........................................................................ 918 E-18 Backup lamp does not light or it keeps lighting up....................................................................... 920 E-19 Backup alarm does not sound or it keeps sounding......................................................................... 923 E-20 Horn does not sound or it keeps sounding................................................................................. 926 E-21 Alarm buzzer does not sound or it keeps sounding......................................................................... 928 E-22 Air conditioner does not operate or stop................................................................................. 930 E-23 The KOMTRAX system does not work properly................................................................................ 933 500 Troubleshooting of hydraulic and mechanical system (H-mode)................................................................... 937 Method of using troubleshooting chart......................................................................................... 939 Failure code and cause table.................................................................................................. 942 H-1 The machine does not start................................................................................................ 944 H-2 The travel speed is slow.................................................................................................. 945 H-3 The traction force is weak................................................................................................ 946 H-4 Engine stalls when traveling or engine speed drops excessively............................................................ 947 H-5 Shift range is not shifted................................................................................................ 948 H-6 The steering wheel does not turn.......................................................................................... 949 H-7 The steering wheel is heavy............................................................................................... 950 H-8 Steering wheel shakes or jerks............................................................................................ 951 H-9 Machine deviates naturally to one side when traveling..................................................................... 951 H-10 The brake does not work or does not work well............................................................................ 952 H-11 The brake is not released or is dragged.................................................................................. 953 H-12 The lift arm does not rise or lower...................................................................................... 954 H-13 The lift arm moves slowly or the lift arm rising force is insufficient................................................... 955 H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 956 H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air).......................................... 956 H-16 Hydraulic drifts of the lift arm occur often............................................................................. 956 H-17 The lift arm wobbles during operation.................................................................................... 956 H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily................................ 957 H-19 The bucket does not tilt back............................................................................................ 958 H-20 The bucket moves slowly or the tilting-back force is insufficient........................................................ 959 H-21 The bucket comes to operate slowly in the midst of tilting-back.......................................................... 960 H-22 The bucket cylinder cannot hold down the bucket.......................................................................... 960 H-23 Hydraulic drifts of the bucket occur often............................................................................... 960 H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)................................... 960 H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily................................... 961 H-26 The control levers of the lift arm and bucket do not move smoothly and heavy............................................. 961 H-27 The ECSS does not operate and machine pitches and bounces................................................................ 962 H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)................................. 963 600 Troubleshooting of engine (S-mode)............................................................................................ 965 Method of using troubleshooting charts........................................................................................ 966 S-1 Starting performance is poor.............................................................................................. 970 S-2 Engine does not start..................................................................................................... 972 S-3 Engine does not pick up smoothly.......................................................................................... 975 S-4 Engine stops during operations............................................................................................ 976 S-5 Engine does not rotate smoothly........................................................................................... 977 S-6 Engine lacks output (or lacks power)...................................................................................... 978 S-7 Exhaust smoke is black (incomplete combustion)............................................................................ 979 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................................... 980 S-9 Oil becomes contaminated quickly.......................................................................................... 981 S-10 Fuel consumption is excessive............................................................................................ 982 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down).................................................... 983 S-12 Oil pressure drops....................................................................................................... 984 S-13 Oil level rises (Entry of coolant or fuel)............................................................................... 985 S-14 Coolant temperature becomes too high (overheating)....................................................................... 986 S-15 Abnormal noise is made................................................................................................... 987 S-16 Vibration is excessive................................................................................................... 988 50 Disassembly and assembly........................................................................................................... 989 100 General information on disassembly and assembly............................................................................... 989 How to read this manual....................................................................................................... 990 Coating materials list........................................................................................................ 992 Special tool list............................................................................................................. 995 Sketches of special tools..................................................................................................... 999 200 Engine and cooling system.....................................................................................................1007 Removal and installation of fuel supply pump assembly.........................................................................1008 Removal and installation of fuel injector assembly............................................................................1010 Removal and installation of cylinder head assembly............................................................................1018 Removal and installation of engine hood assembly..............................................................................1030 Removal and installation of radiator..........................................................................................1033 Removal and installation of air aftercooler...................................................................................1036 Removal and installation of hydraulic oil cooler assembly.....................................................................1038 Removal and installation of engine assembly...................................................................................1040 Removal and installation of engine front oil seal assembly....................................................................1046 Removal and installation of engine rear oil seal assembly.....................................................................1049 Removal and installation of cooling fan and fan motor assembly................................................................1052 Removal and installation of fuel tank assembly................................................................................1055 310 Power train, Part 1...........................................................................................................1057 Removal and installation of transfer assembly.................................................................................1058 Disassembly and assembly of transfer assembly.................................................................................1061 Removal and installation of parking brake assembly............................................................................1080 Disassembly and assembly of parking brake assembly............................................................................1081 320 Power train, Part 2...........................................................................................................1087 Removal and installation of front axle assembly...............................................................................1088 Removal and installation of rear axle assembly................................................................................1090 Disassembly and assembly of axle housing assembly.............................................................................1093 Disassembly and assembly of differential assembly.............................................................................1105 400 Undercarriage and frame.......................................................................................................1129 Removal and installation of center hinge pin..................................................................................1130 Removal and installation of counterweight assembly............................................................................1140 500 Hydraulic system..............................................................................................................1143 Removal and installation of HST pump and 4-gear pump assembly.................................................................1144 Disassembly and assembly of HST pump assembly.................................................................................1147 Removal and installation of HST motor 1 assembly..............................................................................1174 Removal and installation of HST motor 2 assembly..............................................................................1176 Disassembly and assembly of HST motor assembly................................................................................1178 Removal and installation of work equipment control valve assembly.............................................................1194 Removal and installation of hydraulic tank assembly...........................................................................1196 Disassembly and assembly of hydraulic cylinder assembly.......................................................................1198 600 Work equipment................................................................................................................1205 Removal and installation of work equipment assembly...........................................................................1206 700 Cab and its attachments.......................................................................................................1213 Removal and installation of operator's cab and floor frame assembly...........................................................1214 Removal and installation of operator's cab glass (Stuck glass)................................................................1220 Disassembly and assembly of operator's seat assembly..........................................................................1228 Removal and installation of air conditioner unit..............................................................................1238 800 Electrical system.............................................................................................................1243 Removal and installation of monitor panel.....................................................................................1244 Removal and installation of engine controller assembly........................................................................1246 Removal and installation of HST controller assembly...........................................................................1247 Removal and installation of KOMTRAX terminal assembly.........................................................................1248 90 Diagrams and drawings..............................................................................................................1249 100 Hydraulic diagrams and drawings...............................................................................................1249 Central lubrication system....................................................................................................1250 Hydraulic circuit diagram WA320-6.............................................................................................1251 Hydraulic circuit diagram WA320PZ-6...........................................................................................1252 200 Electrical diagrams and drawings..............................................................................................1253 Electrical circuit diagram (1/9)..............................................................................................1255 Electrical circuit diagram (2/9)..............................................................................................1256 Electrical circuit diagram (3/9)..............................................................................................1257 Electrical circuit diagram (4/9)..............................................................................................1258 Electrical circuit diagram (5/9)..............................................................................................1259 Electrical circuit diagram (6/9)..............................................................................................1260 Electrical circuit diagram (7/9)..............................................................................................1261 Electrical circuit diagram (8/9)..............................................................................................1262 Electrical circuit diagram (9/9)..............................................................................................1263 Specific electrical circuit diagram (1/4).....................................................................................1264 Specific electrical circuit diagram (2/4).....................................................................................1265 Specific electrical circuit diagram (3/4).....................................................................................1266 Specific electrical circuit diagram (4/4).....................................................................................1267 Connector list and stereogram.................................................................................................1268
DESCRIPTION:
KOMATSU WA320-6 WA320PZ-6 SHOP MANUAL VEBM620100 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) 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, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 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 warning signs in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
S.S 26/12/24
