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Komatsu WA320-6, WA320PZ-6 Wheel Loader Shop Manual SEN04162-07 PDF
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Komatsu WA320-6, WA320PZ-6 Wheel Loader Shop Manual
SERIAL NUMBERS:
WA320- 70001 and up
WA320PZ-70001 and up
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Description
Komatsu WA320-6, WA320PZ-6 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA320-6, WA320PZ-6 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA320-6, WA320PZ-6
Serial Number: 70001 and up
Book Code: SEN04162-07
Language: English
Pages: 1306
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA320-6, WA320PZ-6 Wheel Loader Shop Manual
HOW TO READ THE SHOP MANUAL:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. FOREWORD:
This section explains the safety and basic information.
01. GENERAL:
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. TESTING AND ADJUSTING:
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume):
• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu WA320-6, WA320PZ-6 Wheel Loader Shop Manual
COVER ................................................................................................................................ 1 00 Index and foreword................................................................................................................. 0 100 Index......................................................................................................................... 3 Composition of shop manual.................................................................................................... 4 Table of contents............................................................................................................. 6 200 Foreword and general information.............................................................................................. 17 Safety notice................................................................................................................. 18 How to read the shop manual................................................................................................... 23 Explanation of terms for maintenance standard................................................................................. 25 Handling of electric equipment and hydraulic component........................................................................ 27 Handling of connectors newly used for engines................................................................................. 36 How to read electric wire code................................................................................................ 39 Precautions when carrying out operation....................................................................................... 42 Method of disassembling and connecting push-pull type coupler................................................................. 45 Standard tightening torque table.............................................................................................. 48 Conversion table.............................................................................................................. 52 01 Specification...................................................................................................................... 0 100 Specification and technical data.............................................................................................. 59 Specification dimension drawing............................................................................................... 61 Specifications................................................................................................................ 62 Weight table.................................................................................................................. 66 Table of fuel, coolant and lubricants......................................................................................... 68 10 Structure, function and maintenance standard....................................................................................... 0 100 Engine and cooling system..................................................................................................... 71 Engine mount and transfer mount............................................................................................... 72 Damper........................................................................................................................ 73 Cooling system................................................................................................................ 74 Cooling system hydraulic piping diagram....................................................................................... 75 Cooling fan motor............................................................................................................. 77 200 Power train................................................................................................................... 87 Power train................................................................................................................... 89 Power train system diagram.................................................................................................... 90 Drive shaft................................................................................................................... 92 HST hydraulic piping diagram.................................................................................................. 93 HST pump...................................................................................................................... 94 HST motor..................................................................................................................... 102 Transfer...................................................................................................................... 108 Clutch solenoid valve......................................................................................................... 119 Axle.......................................................................................................................... 120 Differential.................................................................................................................. 122 Torque proportioning differential............................................................................................. 127 Limited slip differential..................................................................................................... 130 Final drive................................................................................................................... 134 300 Steering system............................................................................................................... 139 Steering piping diagram....................................................................................................... 141 Steering column............................................................................................................... 142 Priority valve................................................................................................................ 143 Orbit-roll valve.............................................................................................................. 146 Cushion valve................................................................................................................. 154 Steering cylinder............................................................................................................. 155 Emergency steering piping diagram............................................................................................. 157 Emergency steering valve...................................................................................................... 158 Steering relief valve......................................................................................................... 161 400 Brake system.................................................................................................................. 163 Brake piping diagram.......................................................................................................... 165 Charge valve.................................................................................................................. 166 Brake valve................................................................................................................... 170 Inching valve................................................................................................................. 174 Accumulator (for brake)....................................................................................................... 175 Slack adjuster................................................................................................................ 176 Brake......................................................................................................................... 178 Parking brake control......................................................................................................... 183 Parking brake................................................................................................................. 184 500 Undercarriage and frame....................................................................................................... 187 Axle mount and center hinge pin............................................................................................... 188 Tires......................................................................................................................... 193 600 Hydraulic system.............................................................................................................. 195 Work equipment hydraulic piping diagram....................................................................................... 196 Work equipment control lever linkage.......................................................................................... 200 Hydraulic tank................................................................................................................ 204 4-gear pump................................................................................................................... 206 Work equipment control valve.................................................................................................. 208 Cut-off valve................................................................................................................. 234 PPC valve..................................................................................................................... 237 Lock valve.................................................................................................................... 252 Accumulator (for PPC circuit)................................................................................................. 253 ECSS valve.................................................................................................................... 255 Accumulator (for ECSS)........................................................................................................ 257 700 Work equipment................................................................................................................ 259 Work equipment linkage........................................................................................................ 260 Bucket........................................................................................................................ 264 Bucket positioner and boom kick-out........................................................................................... 268 Work equipment cylinder....................................................................................................... 280 800 Cab and its attachments....................................................................................................... 283 Cab........................................................................................................................... 285 Air conditioner............................................................................................................... 286 910 Electrical system, Part 1..................................................................................................... 299 Machine monitor system........................................................................................................ 300 Machine monitor............................................................................................................... 304 920 Electrical system, Part 2..................................................................................................... 327 Electrical system (HST controller system)..................................................................................... 328 HST controller................................................................................................................ 344 ECSS system................................................................................................................... 346 KOMTRAX system................................................................................................................ 348 Engine starting circuit....................................................................................................... 350 Engine stopping circuit....................................................................................................... 352 Preheating circuit............................................................................................................ 353 Engine output derating function............................................................................................... 354 Automatic warm-up function.................................................................................................... 354 Parking brake circuit......................................................................................................... 356 Coupler plunger control system................................................................................................ 358 Max. traction switch.......................................................................................................... 359 Multi-function knob........................................................................................................... 360 Sensor........................................................................................................................ 361 20 Standard value table............................................................................................................... 0 100 Standard service value table.................................................................................................. 369 Standard service value table for engine....................................................................................... 370 Standard service value table for chassis...................................................................................... 371 30 Testing and adjusting.............................................................................................................. 0 110 Testing and adjusting, Part 1................................................................................................. 379 Tools for testing, adjusting, and troubleshooting............................................................................. 381 Measuring engine speed........................................................................................................ 386 Measuring exhaust gas color................................................................................................... 388 Adjusting valve clearance..................................................................................................... 390 Measuring compression pressure................................................................................................ 392 Measuring blow-by pressure.................................................................................................... 395 Measuring engine oil pressure................................................................................................. 396 Measuring intake air (boost) pressure......................................................................................... 397 Handling fuel system equipment................................................................................................ 399 Releasing residual pressure in fuel system.................................................................................... 399 Measuring fuel pressure....................................................................................................... 400 Measuring fuel return rate and leakage........................................................................................ 402 Bleeding air from fuel circuit................................................................................................ 406 Checking leakage in fuel system............................................................................................... 407 Handling cylinder cut-out mode operation...................................................................................... 408 Handling no-injection cranking operation...................................................................................... 408 Handling controller voltage circuit........................................................................................... 409 Check of muffler and muffler stack for looseness and damage................................................................... 409 Check of muffler function..................................................................................................... 410 Check of installed condition of cylinder head and manifolds................................................................... 410 Check of engine piping for damage and looseness............................................................................... 411 Testing and adjusting air conditioner compressor belt tension................................................................. 411 Replacing alternator belt..................................................................................................... 412 120 Testing and adjusting, Part 2................................................................................................. 415 Checking operating force of accelerator pedal................................................................................. 417 Checking directional lever.................................................................................................... 418 Testing and adjusting HST oil pressure........................................................................................ 419 Testing clutch control pressure............................................................................................... 423 Testing and adjusting steering wheel.......................................................................................... 424 Testing and adjusting steering oil pressure................................................................................... 426 Bleeding air from steering circuit............................................................................................ 428 Testing hydraulic fan......................................................................................................... 429 Measuring brake pedal......................................................................................................... 431 Testing and adjusting brake pedal linkage..................................................................................... 432 Measuring brake performance................................................................................................... 433 Testing and adjusting accumulator charge pressure............................................................................. 434 Testing wheel brake oil pressure.............................................................................................. 436 Testing wear of brake disc.................................................................................................... 439 Bleeding air from wheel brake circuit......................................................................................... 440 Releasing residual pressure in brake accumulator circuit...................................................................... 441 Testing parking brake performance............................................................................................. 442 Testing and adjusting parking brake control cable............................................................................. 443 Measuring and adjusting work equipment control lever.......................................................................... 444 Testing and adjusting work equipment hydraulic pressure....................................................................... 445 Testing work equipment PPC oil pressure....................................................................................... 446 Bleeding air from hydraulic circuit........................................................................................... 448 Releasing remaining pressure in hydraulic circuit............................................................................. 449 Testing and adjusting bucket positioner....................................................................................... 450 Testing and adjusting of boom kick-out switch................................................................................. 451 Checking proximity switch operation pilot lamp................................................................................ 452 Procedure for testing diodes.................................................................................................. 453 Preparation work for troubleshooting for electric system...................................................................... 454 Starting KOMTRAX terminal operations.......................................................................................... 458 Indicator lamps of KOMTRAX terminal........................................................................................... 462 130 Testing and adjusting, Part 3................................................................................................. 467 Adjusting machine monitor..................................................................................................... 468 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor........................................ 469 Special functions of machine monitor (EMMS)................................................................................... 471 Pm clinic inspection chart.................................................................................................... 524 40 Troubleshooting.................................................................................................................... 0 100 Failure code table and fuse locations......................................................................................... 527 Failure codes table........................................................................................................... 528 Fuse locations................................................................................................................ 534 200 General information on troubleshooting........................................................................................ 539 Points to remember when troubleshooting....................................................................................... 540 Sequence of events in troubleshooting......................................................................................... 541 Testing before troubleshooting................................................................................................ 542 Classification and procedures of troubleshooting.............................................................................. 543 Information contained in troubleshooting table................................................................................ 546 Connection table for connector pin numbers.................................................................................... 548 T- branch box and T- branch adapter table..................................................................................... 584 310 Troubleshooting by failure code (Display of code), Part 1..................................................................... 589 Failure code [2G40ZG] Brake: Oil pressure reduction........................................................................... 590 Failure code [6091NX] HST filter: Clogging.................................................................................... 592 Failure code [989FN1] Travel speed: Overrun alarm............................................................................. 593 Failure code [AA1ANX] Air cleaner: Clogging................................................................................... 594 Failure code [AB00L6] Alternator R system: Hot short.......................................................................... 596 Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage...................................... 598 Failure code [B@BAZG] Engine: Oil pressure reduction.......................................................................... 600 Failure code [B@BAZK] Engine oil: Low level................................................................................... 601 Failure code [B@BCNS] Engine: Overheat........................................................................................ 602 Failure code [B@BCZK] Engine: Low coolant level............................................................................... 604 Failure code [B@C6NS] Front brake: High oil temperature....................................................................... 606 Failure code [B@CRNS] HST: High oil temperature............................................................................... 607 320 Troubleshooting by failure code (Display of code), Part 2..................................................................... 609 Failure code [CA111] Abnormality in engine controller......................................................................... 611 Failure code [CA115] Engine Ne or Bkup speed sensor error..................................................................... 612 Failure code [CA122] Charge pressure sensor high error........................................................................ 614 Failure code [CA123] Charge pressure sensor low error......................................................................... 616 Failure code [CA131] Throttle sensor high error............................................................................... 618 Failure code [CA132] Throttle sensor low error................................................................................ 620 Failure code [CA144] Coolant sensor high error................................................................................ 622 Failure code [CA145] Coolant sensor low error................................................................................. 624 Failure code [CA153] Charge temperature sensor high error..................................................................... 626 Failure code [CA154] Charge temperature sensor low error...................................................................... 628 Failure code [CA155] Derating of speed by abnormally high charge temperature.................................................. 630 Failure code [CA187] Sensor power supply 2 low error.......................................................................... 632 Failure code [CA221] Atmospheric pressure sensor high error................................................................... 634 Failure code [CA222] Atmospheric sensor low error............................................................................. 636 Failure code [CA227] Sensor power supply 2 high error......................................................................... 638 Failure code [CA234] Engine overspeed......................................................................................... 639 Failure code [CA238] Ne speed sensor power supply error....................................................................... 640 Failure code [CA271] IMV (IMA) Short circuit.................................................................................. 641 Failure code [CA272] IMV (IMA) Disconnection.................................................................................. 642 Failure code [CA322] Injector #1 open/short error............................................................................. 644 Failure code [CA323] Injector #5 open/short error............................................................................. 646 Failure code [CA324] Injector #3 open/short error............................................................................. 648 Failure code [CA325] Injector #6 open/short error............................................................................. 650 Failure code [CA331] Injector #2 open/short error............................................................................. 652 Failure code [CA332] Injector #4 open/short error............................................................................. 654 Failure code [CA342] Calibration code inconsistency........................................................................... 656 Failure code [CA351] Injectors drive circuit error............................................................................ 658 Failure code [CA352] Sensor power supply 1 low error.......................................................................... 660 Failure code [CA386] Sensor power supply 1 high error......................................................................... 662 330 Troubleshooting by failure code (Display of code), Part 3..................................................................... 665 Failure code [CA428] Abnormally high level in water sensor.................................................................... 668 Failure code [CA429] Abnormally low level in water sensor..................................................................... 670 Failure code [CA431] Idle validation switch error............................................................................. 672 Failure code [CA432] Idle validation action error............................................................................. 676 Failure code [CA435] Engine oil pressure switch error......................................................................... 680 Failure code [CA441] Battery voltage low error................................................................................ 681 Failure code [CA442] Battery voltage high error............................................................................... 684 Failure code [CA449] Common rail pressure high error 2........................................................................ 686 Failure code [CA451] Common rail pressure sensor high error................................................................... 688 Failure code [CA452] Common rail pressure sensor low error.................................................................... 690 Failure code [CA488] Derating of torque by abnormally high charge temperature................................................. 692 Failure code [CA553] Common rail pressure high error 1........................................................................ 693 Failure code [CA559] Supply pump pressure very low error...................................................................... 694 Failure code [CA689] Engine Ne speed sensor error............................................................................. 696 Failure code [CA731] Engine Bkup speed sensor phase error..................................................................... 698 Failure code [CA757] All continuous data lost error........................................................................... 699 Failure code [CA778] Engine Bkup speed sensor error........................................................................... 702 Failure code [CA1633] KOMNET datalink timeout error........................................................................... 704 Failure code [CA2185] Throttle sensor supply voltage high error............................................................... 708 Failure code [CA2186] Throttle sensor power supply low error.................................................................. 710 Failure code [CA2249] Supply pump pressure very low error 2................................................................... 712 Failure code [CA2311] Abnormality in IMV (IMA) solenoid....................................................................... 714 Failure code [CA2555] Intake heater relay disconnection error................................................................. 716 Failure code [CA2556] Intake heater relay short circuit error................................................................. 718 340 Troubleshooting by failure code (Display of code), Part 4..................................................................... 721 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short............................................................ 722 Failure code [D192KY] ECSS solenoid relay: Hot short.......................................................................... 724 Failure code [D1B0KA] HST safety relay: Disconnection......................................................................... 726 Failure code [D1B0KB] HST safety relay: Ground fault.......................................................................... 728 Failure code [D1B0KY] HST safety relay: Hot short............................................................................. 730 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection................................................................ 732 Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection........................................................... 734 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection........................................................... 736 Failure code [DAJ0KK] HST controller power supply: Low voltage................................................................ 740 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality............................................................. 742 Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault.............................................. 744 Failure code [DAJ1L6] HST controller main power line: Hot short............................................................... 746 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage........................................................... 748 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness.............................. 750 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault............................... 752 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range............................................................. 754 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals................................. 756 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection............................................................ 757 Failure code [DAJRMA] HST controller: Disagreement in option selection........................................................ 763 350 Troubleshooting by failure code (Display of code), Part 5..................................................................... 765 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line................................................. 766 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality........................................................ 772 Failure code [DD1NLD] Fan reverse switch signal: Abnormality.................................................................. 774 Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short.................................................. 776 Failure code [DDB6KB] Parking brake indicator signal: Ground fault............................................................ 778 Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble.... 780 Failure code [DDB6L0] Parking brake reminder signal: Ground fault............................................................. 782 Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short................................................. 784 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault............................................ 786 Failure code [DDD7KY] Travel speed control dial signal: Hot short............................................................. 788 Failure code [DDE5MA] Emergency steering operation switch: Disconnection...................................................... 790 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault................................................................... 792 Failure code [DDK6KY] FNR lever: Hot short.................................................................................... 796 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)............................................ 798 360 Troubleshooting by failure code (Display of code), Part 6..................................................................... 801 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault.......................................... 802 Failure code [DF10KB] Travel speed range selector switch: Hot short........................................................... 806 Failure code [DGH1KX] HST oil temperature sensor: Ground fault................................................................ 808 Failure code [DGR2KB] Brake oil temperature sensor: Ground fault.............................................................. 809 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short................................................... 810 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault..................................................... 812 Failure code [DHH1KY] HST oil pressure sensor: Hot short...................................................................... 814 Failure code [DHTCL6] HST filter clogging sensor: Functional defect........................................................... 816 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short.............................................................. 818 Failure code [DLT3KX] Travel speed sensor B: Abnormality...................................................................... 820 Failure code [DLT4KX] Travel speed sensor A: Abnormality...................................................................... 824 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality.................................................................. 826 Failure code [DV00KY] Alarm buzzer: Hot short................................................................................. 828 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault............................................................ 830 Failure code [DW26KY] Motor 2 solenoid: Hot short............................................................................. 832 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short................................................................. 834 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault................................................ 836 370 Troubleshooting by failure code (Display of code), Part 7..................................................................... 839 Failure code [DX16KA] Fan EPC solenoid: Disconnection......................................................................... 840 Failure code [DX16KB] Fan EPC solenoid: Ground fault.......................................................................... 841 Failure code [DX16KY] Fan EPC solenoid: Hot short............................................................................. 842 Failure code [DX19KA] Motor 1 solenoid: Disconnection......................................................................... 844 Failure code [DX19KB] Motor 1 solenoid: Ground fault.......................................................................... 846 Failure code [DX19KY] Motor 1 solenoid: Hot short............................................................................. 848 Failure code [DX20KA] Clutch EPC solenoid: Disconnection...................................................................... 850 Failure code [DX20KB] Clutch EPC solenoid: Ground fault....................................................................... 852 Failure code [DX20KY] Clutch EPC solenoid: Hot short.......................................................................... 854 Failure code [DXH7KB] Reverse solenoid: Ground fault.......................................................................... 856 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short............................................................... 858 Failure code [DXH8KB] Forward solenoid: Ground fault.......................................................................... 860 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short............................................................... 862 Failure code [J141N1] Steering pump: Overrun alarm............................................................................ 864 Failure code [M100N1] HST pump: Overrun alarm................................................................................. 864 Failure code [M400N1] Motor 1: Overrun alarm.................................................................................. 865 400 Troubleshooting of electrical system (E-mode)................................................................................. 867 E-1 Engine does not start..................................................................................................... 869 E-2 Preheater does not operate normally....................................................................................... 876 E-3 Travel speed is low or high............................................................................................... 880 E-4 ECSS does not operate..................................................................................................... 886 E-5 ECSS keeps operating...................................................................................................... 889 E-6 Defective boom kick-out function and cancellation......................................................................... 892 E-7 Defective bucket positioner function and cancellation..................................................................... 896 E-8 Defective lift arm FLOATING holding function and cancellation............................................................. 900 E-9 Travel direction selection system does not function....................................................................... 904 E-10 Fan does not reverse..................................................................................................... 908 E-11 Fan keeps rotating in reverse............................................................................................ 912 E-12 Wiper does not operate................................................................................................... 914 E-13 Windshield washer does not operate....................................................................................... 918 E-14 Headlamp, clearance lamp and tail lamp do not light up or go off......................................................... 922 E-15 Working lamp does not light up or go off................................................................................. 930 E-16 Turn signal lamp and hazard lamp do not light up or go off............................................................... 936 E-17 Brake lamp does not light or it keeps lighting up........................................................................ 942 E-18 Backup lamp does not light or it keeps lighting up....................................................................... 944 E-19 Backup alarm does not sound or it keeps sounding......................................................................... 947 E-20 Horn does not sound or it keeps sounding................................................................................. 950 E-21 Alarm buzzer does not sound or it keeps sounding......................................................................... 952 E-22 Air conditioner does not operate or stop................................................................................. 954 E-23 The KOMTRAX system does not work properly................................................................................ 958 500 Troubleshooting of hydraulic and mechanical system (H-mode)................................................................... 961 Method of using troubleshooting chart......................................................................................... 963 Failure code and cause table.................................................................................................. 966 H-1 The machine does not start................................................................................................ 968 H-2 The travel speed is slow.................................................................................................. 969 H-3 The traction force is weak................................................................................................ 970 H-4 Engine stalls when traveling or engine speed drops excessively............................................................ 971 H-5 Shift range is not shifted................................................................................................ 972 H-6 The steering wheel does not turn.......................................................................................... 973 H-7 The steering wheel is heavy............................................................................................... 974 H-8 Steering wheel shakes or jerks............................................................................................ 975 H-9 Machine deviates naturally to one side when traveling..................................................................... 975 H-10 The brake does not work or does not work well............................................................................ 976 H-11 The brake is not released or is dragged.................................................................................. 977 H-12 The lift arm does not rise or lower...................................................................................... 978 H-13 The lift arm moves slowly or the lift arm rising force is insufficient................................................... 979 H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 980 H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air).......................................... 980 H-16 Hydraulic drifts of the lift arm occur often............................................................................. 980 H-17 The lift arm wobbles during operation.................................................................................... 980 H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily................................ 981 H-19 The bucket does not tilt back............................................................................................ 982 H-20 The bucket moves slowly or the tilting-back force is insufficient........................................................ 983 H-21 The bucket comes to operate slowly in the midst of tilting-back.......................................................... 984 H-22 The bucket cylinder cannot hold down the bucket.......................................................................... 984 H-23 Hydraulic drifts of the bucket occur often............................................................................... 984 H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)................................... 984 H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily................................... 985 H-26 The control levers of the lift arm and bucket do not move smoothly and heavy............................................. 985 H-27 The ECSS does not operate and machine pitches and bounces................................................................ 986 H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)................................. 987 600 Troubleshooting of engine (S-mode)............................................................................................ 989 Method of using troubleshooting charts........................................................................................ 990 S-1 Starting performance is poor.............................................................................................. 994 S-2 Engine does not start..................................................................................................... 996 S-3 Engine does not pick up smoothly.......................................................................................... 999 S-4 Engine stops during operations............................................................................................1000 S-5 Engine does not rotate smoothly...........................................................................................1001 S-6 Engine lacks output (or lacks power)......................................................................................1002 S-7 Exhaust smoke is black (incomplete combustion)............................................................................1003 S-8 Oil consumption is excessive (or exhaust smoke is blue)...................................................................1004 S-9 Oil becomes contaminated quickly..........................................................................................1005 S-10 Fuel consumption is excessive............................................................................................1006 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....................................................1007 S-12 Oil pressure drops.......................................................................................................1008 S-13 Oil level rises (Entry of coolant or fuel)...............................................................................1009 S-14 Coolant temperature becomes too high (overheating).......................................................................1010 S-15 Abnormal noise is made...................................................................................................1011 S-16 Vibration is excessive...................................................................................................1012 50 Disassembly and assembly........................................................................................................... 0 100 General information on disassembly and assembly...............................................................................1015 How to read this manual.......................................................................................................1016 Coating materials list........................................................................................................1018 Special tool list.............................................................................................................1021 Sketches of special tools.....................................................................................................1025 200 Engine and cooling system.....................................................................................................1033 Removal and installation of fuel supply pump assembly.........................................................................1034 Removal and installation of fuel injector assembly............................................................................1037 Removal and installation of cylinder head assembly............................................................................1045 Removal and installation of engine hood assembly..............................................................................1057 Removal and installation of radiator..........................................................................................1060 Removal and installation of air aftercooler...................................................................................1063 Removal and installation of hydraulic oil cooler assembly.....................................................................1065 Removal and installation of engine assembly...................................................................................1067 Removal and installation of engine front oil seal assembly....................................................................1073 Removal and installation of engine rear oil seal assembly.....................................................................1076 Removal and installation of cooling fan and fan motor assembly................................................................1079 Removal and installation of fuel tank assembly................................................................................1082 310 Power train, Part 1...........................................................................................................1085 Removal and installation of transfer assembly.................................................................................1086 Disassembly and assembly of transfer assembly.................................................................................1089 Removal and installation of parking brake assembly............................................................................1108 Disassembly and assembly of parking brake assembly............................................................................1109 320 Power train, Part 2...........................................................................................................1115 Removal and installation of front axle assembly...............................................................................1116 Removal and installation of rear axle assembly................................................................................1118 Disassembly and assembly of axle housing assembly.............................................................................1121 Disassembly and assembly of differential assembly.............................................................................1133 400 Undercarriage and frame.......................................................................................................1157 Removal and installation of center hinge pin..................................................................................1158 Removal and installation of counterweight assembly............................................................................1168 500 Hydraulic system..............................................................................................................1171 Removal and installation of HST pump and 4-gear pump assembly.................................................................1172 Disassembly and assembly of HST pump assembly.................................................................................1175 Removal and installation of HST motor 1 assembly..............................................................................1202 Removal and installation of HST motor 2 assembly..............................................................................1204 Disassembly and assembly of HST motor assembly................................................................................1206 Removal and installation of work equipment control valve assembly.............................................................1222 Removal and installation of hydraulic tank assembly...........................................................................1224 Disassembly and assembly of hydraulic cylinder assembly.......................................................................1226 600 Work equipment................................................................................................................1235 Removal and installation of work equipment assembly...........................................................................1236 700 Cab and its attachments.......................................................................................................1243 Removal and installation of operator's cab and floor frame assembly...........................................................1244 Removal and installation of operator's cab glass (Stuck glass)................................................................1250 Disassembly and assembly of operator's seat assembly..........................................................................1258 Removal and installation of air conditioner unit..............................................................................1268 800 Electrical system.............................................................................................................1273 Removal and installation of monitor panel.....................................................................................1274 Removal and installation of engine controller assembly........................................................................1276 Removal and installation of HST controller assembly...........................................................................1277 Removal and installation of KOMTRAX terminal assembly.........................................................................1278 90 Diagrams and drawings.............................................................................................................. 0 100 Hydraulic diagrams and drawings...............................................................................................1281 Automatic greasing circuit diagram............................................................................................1282 Hydraulic circuit diagram.....................................................................................................1285 200 Electrical diagrams and drawings..............................................................................................1289 Common electrical circuit diagram.............................................................................................1291 Connector list and stereogram.................................................................................................1304
KOMATSU WA320-6, WA320PZ-6 WHEEL LOADER SHOP MANUAL SEN04162-07 PDF:
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