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Komatsu WA320-6 Wheel Loader Shop Manual – PDF DOWNLOAD
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Komatsu WA320-6 Wheel Loader Shop Manual
SERIAL NUMBERS : WA320-6 A34001 – A34999
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Description
Komatsu WA320-6 Wheel Loader Shop Manual
FILE DETAILS:
Komatsu WA320-6 Wheel Loader Shop Manual
Brands: Komatsu
Equipment Type: Wheel Loader
Manuals Type: Shop Manual
Machine Model: WA320-6
Serial Number: A34001 – A34999
Book Code: CEBM019803
Language: English
Pages: 1392
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu WA320-6 Wheel Loader Shop Manual
1 GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
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 checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
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
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
AIR CONDITIONING
This section explains the air conditioning system, structure and function, troubleshooting, disassembly, and assembly.
DIAGRAMS AND DRAWINGS
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu WA320-6 Wheel Loader Shop Manual
CEBM019803 - WA320-6 sn A34001 - A34999........................................................... 1 CONTENTS...................................................................................... 2 REVISED PAGES................................................................................. 3 SAFETY........................................................................................ 15 Safety Notice............................................................................. 15 IMPORTANT SAFETY NOTICE............................................................... 15 General Precautions................................................................... 15 Preparations for Work................................................................. 16 Precautions During Work............................................................... 16 Seat Belt Inspection...................................................................... 17 GENERAL....................................................................................... 18 HOW TO READ THE SHOP MANUAL................................................................... 19 Volumes................................................................................... 19 Distribution and Updating................................................................. 19 Filing Method............................................................................. 19 Revised Edition Mark...................................................................... 19 Revisions................................................................................. 19 Symbols................................................................................... 19 HOISTING INSTRUCTIONS......................................................................... 20 Hoisting.................................................................................. 20 Making Signs/Hand Signals................................................................. 20 Precautions............................................................................... 20 Precautions for Sling Work............................................................ 20 Precautions for Using Mobile Crane.................................................... 21 Precautions for Using Overhead Hoist Crane............................................ 21 Selecting Wire Ropes...................................................................... 22 AIR CONDITIONER CIRCUITS...................................................................... 23 Precautions for Handling Hoses and Tubes.................................................. 23 Disconnecting Hoses and Tubes......................................................... 23 Connecting Hoses and Tubes............................................................ 23 MAINTENANCE STANDARD TERMS.................................................................... 24 HANDLING ELECTRIC AND HYDRAULIC EQUIPMENT..................................................... 26 Handling Electric Equipment............................................................... 26 Handling Wiring Harnesses and Connectors.............................................. 26 Main Failures Occurring in Wiring Harness............................................. 26 Removing, Installing, and Drying Connectors and Wiring Harnesses...................... 27 Handling Controller................................................................... 31 Troubleshooting Electric Circuits..................................................... 31 Handling Hydraulic Equipment.............................................................. 32 Handling Connectors Used for Engines...................................................... 33 Slide Lock Type....................................................................... 33 Pull Lock Type........................................................................ 34 Push Lock Type........................................................................ 34 Turn-housing Type (Round Green Connector)............................................. 36 PRECAUTIONS FOR OPERATIONS.................................................................... 37 Precautions When Carrying Out Removal Work................................................ 37 Precautions When Carrying Out Installation Work........................................... 38 Precautions When Completing the Operation................................................. 39 PUSH-PULL COUPLER............................................................................. 40 Type 1.................................................................................... 40 Disconnection......................................................................... 40 Connection............................................................................ 40 Type 2.................................................................................... 41 Disconnection......................................................................... 41 Connection............................................................................ 41 Type 3.................................................................................... 42 Disconnection......................................................................... 42 Connection............................................................................ 42 COATING MATERIALS............................................................................. 43 STANDARD TIGHTENING TORQUE.................................................................... 45 Standard Tightening Tables................................................................ 45 For Bolts and Nuts.................................................................... 45 For Split Flange Bolts................................................................ 46 For O-Ring Boss Piping Joints......................................................... 46 For O-Ring Boss Plugs................................................................. 47 For Hoses (Taper-Seal Type and Face-Seal Type)........................................ 47 For Face Seal Joints.................................................................. 48 For 102, 107, and 114 Engine Series (Bolts and Nuts).................................. 48 For 102, 107, and 114 Engine Series (Eye Joints)...................................... 49 For 102, 107, and 114 Engine Series (Taper Screws).................................... 49 CONVERSION TABLES............................................................................. 50 Method of Using the Conversion Table...................................................... 50 01 GENERAL........................................................................................ 57 SPECIFICATIONS................................................................................ 58 Dimension Drawing......................................................................... 58 Specification Tables...................................................................... 60 WEIGHT TABLE.................................................................................. 66 FUEL, COOLANT, AND LUBRICANTS................................................................. 68 10 STRUCTURE, FUNCTION ANDMAINTENANCE STANDARD.................................................... 71 ENGINE AND COOLING SYSTEM..................................................................... 75 Engine and Transfer Mount................................................................. 75 Damper.................................................................................... 76 Cooling System............................................................................ 78 Cooling System Hydraulic Piping Diagram................................................... 79 Cooling Fan Motor......................................................................... 80 Hydraulic Motor....................................................................... 84 Suction Safety Valve.................................................................. 85 Reversible Valve...................................................................... 87 Flow Control Valve (Continuously Variable Type)....................................... 88 POWER TRAIN SYSTEM............................................................................ 89 Drive Line Components..................................................................... 89 Power Train System Diagram................................................................ 90 Drive Shaft............................................................................... 92 HST Hydraulic Piping Diagram.............................................................. 93 HST Pump.................................................................................. 94 Operation............................................................................. 96 High-Pressure Relief Valve............................................................ 97 Low-pressure Relief Valve............................................................. 99 HST Charge Pump....................................................................... 100 Speed-Related Valve (DA Valve)........................................................ 102 High-Pressure Cutoff Valve............................................................ 103 HST Motor................................................................................. 104 HST Motor 1........................................................................... 104 HST Motor 2........................................................................... 106 EP Servo Valve........................................................................ 108 HA Servo Valve........................................................................ 109 Directional Shuttle Valve............................................................. 110 Transfer.................................................................................. 112 Input Shaft........................................................................... 116 Output Shaft.......................................................................... 120 Outline............................................................................... 124 Operation of Clutch................................................................... 125 Power Transmitting Route.............................................................. 126 Clutch Solenoid Valve................................................................. 128 DRIVE AXLE SYSTEM............................................................................. 130 Front and Rear Axles...................................................................... 130 Front Axle............................................................................ 130 Rear Axle............................................................................. 132 Differential.............................................................................. 134 Front Differential.................................................................... 134 Rear Differential..................................................................... 138 Torque Proportioning Differential..................................................... 142 Limited Slip Differential (if equipped)............................................... 144 Final Drive............................................................................... 148 Front Final Drive..................................................................... 148 Rear Final Drive...................................................................... 150 STEERING SYSTEM............................................................................... 153 Steering Piping Diagram................................................................... 153 Steering Column........................................................................... 154 Priority Valve............................................................................ 155 Orbitrol Valve............................................................................ 159 Operation............................................................................. 162 Connection of Hand Pump and Sleeve.................................................... 166 Cushion Valve............................................................................. 168 Steering Cylinder......................................................................... 170 Emergency Steering Piping Diagram (if equipped)........................................... 172 Emergency Steering Valve (if equipped).................................................... 174 Steering Relief Valve (if equipped)....................................................... 178 BRAKE SYSTEM.................................................................................. 180 Brake Piping Diagram...................................................................... 180 Charge Valve.............................................................................. 182 Brake Valve............................................................................... 186 Braking Operation......................................................................... 188 Inching Valve............................................................................. 191 Accumulator (for Brake)................................................................... 192 Slack Adjuster............................................................................ 194 Brakes.................................................................................... 196 Front Brake........................................................................... 196 Rear Brake............................................................................ 198 Parking Brake System...................................................................... 201 Brake Control......................................................................... 201 Parking Brake......................................................................... 202 UNDERCARRIAGE AND FRAME....................................................................... 204 Axle Mounting and Center Hinge Pin........................................................ 204 Tires..................................................................................... 209 Radial Tire........................................................................... 209 Bias Tire............................................................................. 210 HYDRAULIC SYSTEM.............................................................................. 212 Work Equipment Hydraulic Piping Diagram................................................... 212 Work Equipment Control Lever Linkage...................................................... 214 Multi-Function Mono-Lever Type........................................................ 214 2-Lever Type (if equipped)............................................................ 215 Hydraulic Tank............................................................................ 216 Breather.............................................................................. 217 4-Gear Pump............................................................................... 218 Work Equipment Control Valve.............................................................. 220 2-Spool Type.......................................................................... 220 3-Spool Type.......................................................................... 224 Relief Valve.......................................................................... 228 Safety-Suction Valve.................................................................. 229 Suction Valve......................................................................... 230 Operation of Work Equipment Control Valve............................................. 231 Cutoff Valve.............................................................................. 238 PPC Valve................................................................................. 241 Work Equipment PPC Valve: Mono Lever Type............................................. 241 Work Equipment PPC Valve: 2-Lever Type (if equipped).................................. 247 Attachment PPC Valve.................................................................. 254 Lock Valve (for PPC Circuit).............................................................. 256 Accumulator (for PPC Circuit)............................................................. 257 ECSS Valve................................................................................ 258 Accumulator (for ECSS).................................................................... 261 Work Equipment................................................................................ 262 Work Equipment Linkage.................................................................... 262 Bucket.................................................................................... 264 Bucket Positioner and Boom Kickout........................................................ 266 Operation of Proximity Switch......................................................... 268 Work Equipment Cylinders.................................................................. 274 Lift Cylinder......................................................................... 274 Bucket Cylinder....................................................................... 274 CAB ENVIRONMENT............................................................................... 275 Cab....................................................................................... 275 Air Conditioner........................................................................... 276 Air Conditioner Piping Diagram........................................................ 276 Refrigerant Circuit Diagram........................................................... 278 Air Conditioner Unit.................................................................. 279 Blower and Intake Unit................................................................ 282 Compressor............................................................................ 284 Condenser............................................................................. 285 Receiver.............................................................................. 286 Air Conditioner Panel................................................................. 288 ELECTRICAL SYSTEM............................................................................. 292 Machine Monitor System.................................................................... 292 System Circuit Diagram................................................................ 294 Machine Monitor....................................................................... 296 Items Displayed on Monitor............................................................ 297 Machine Monitor Operation Switches........................................................ 306 Setting Machine Monitor............................................................... 307 Troubleshooting Function.............................................................. 308 Character Display Function............................................................ 308 Operator Mode Functions............................................................... 309 Service Mode Functions................................................................ 312 Input and Output Signals.............................................................. 317 Electrical System (HST Controller System)................................................. 325 Input and Output Signals Diagram...................................................... 325 HST Controller Gearshifting Control Function.......................................... 326 HST Controller Protection Function.................................................... 332 Cooling Fan Control Function.......................................................... 335 System Circuit Diagram................................................................ 340 HST Controller............................................................................ 342 ECSS System............................................................................... 344 ELECTRONIC TRANSMISSION CONTROL............................................................... 346 KOMTRAX Terminal System................................................................... 346 KOMTRAX Terminal...................................................................... 348 Engine Starting Circuit................................................................... 350 Engine Stopping Circuit................................................................... 352 Preheating Circuit........................................................................ 353 Engine Output Lowering Function........................................................... 354 Automatic Warm-up Function................................................................ 354 Parking Brake Circuit..................................................................... 355 Max. Traction Switch (if equipped)........................................................ 357 Multi-Function Knob....................................................................... 358 Modification of Multi-Function Lever.................................................. 359 Sensors................................................................................... 362 Speed Sensor.......................................................................... 362 HST Oil Temperature Sensor............................................................ 364 Brake Oil Temperature Sensor.......................................................... 364 HST Oil Pressure Sensor............................................................... 365 HST Oil Filter Clogging Sensor........................................................ 365 Coolant Level Sensor.................................................................. 366 Fuel Level Sensor..................................................................... 367 Accelerator Pedal Sensor.............................................................. 368 Air Cleaner Clogging Sensor........................................................... 370 Water-in-Fuel Sensor.................................................................. 371 Boom Kick-Out Proximity Switch........................................................ 372 Bucket Positioner Proximity Switch.................................................... 372 20 STANDARD VALUE TABLES.......................................................................... 373 STANDARD VALUE TABLES......................................................................... 375 Standard Value Table for Engine........................................................... 375 Standard Value Table for Chassis.......................................................... 376 MACHINE POSTURE............................................................................... 381 30 TESTING AND ADJUSTING.......................................................................... 383 TOOLS......................................................................................... 387 Tools for Testing, Adjusting, and Troubleshooting......................................... 387 ENGINE COMPONENTS............................................................................. 393 Engine Speed.............................................................................. 393 Measure Engine Speed (Low and High Idle).............................................. 393 Measure HST Stall Speed............................................................... 393 Measure Hydraulic Stall Speed......................................................... 394 Measure HST Stall and Hydraulic Stall (Full Stall) Speed.............................. 394 Exhaust Gas Color......................................................................... 395 Using Handy Smoke Checker A1.......................................................... 395 Using Smoke Meter A2.................................................................. 395 Adjusting Valve Clearance................................................................. 397 Measuring Engine Compression.............................................................. 399 Measuring Blow-by Pressure................................................................ 402 Measuring Engine Oil Pressure............................................................. 404 Intake Air (Boost) Pressure............................................................... 405 Measuring with Monitoring Function.................................................... 405 Measuring with Measuring Tool......................................................... 406 FUEL SYSTEM................................................................................... 407 Handling Fuel System Equipment............................................................ 407 Releasing Residual Pressure in Fuel System................................................ 407 Measuring Fuel Pressure................................................................... 408 Measuring Pressure in Fuel Low-pressure Circuit....................................... 408 Measuring Pressure in Fuel Return Circuit............................................. 409 Measuring Fuel Negative-Pressure Circuit Pressure..................................... 410 Fuel Delivery, Return, and Leak Rate...................................................... 411 Measuring Supply Pump Delivery........................................................ 411 Measuring Return Rate from Supply Pump................................................ 413 Measuring Leakage from Pressure Limiter............................................... 414 Measuring Return Rate from Injector................................................... 415 Bleeding Air from Fuel Circuit............................................................ 416 Testing Leakage in Fuel System............................................................ 417 Handling Reduced Cylinder Mode Operation.................................................. 418 Handling No-Injection Cranking Operation.................................................. 418 Handling Controller Voltage Circuit....................................................... 418 EXHAUST SYSTEM AND PIPING..................................................................... 419 Checking Muffler and Muffler Stack for Looseness and Damage............................... 419 Checking Muffler Function................................................................. 419 Checking Installed Condition of Cylinder Head and Manifolds............................... 419 Checking Engine Piping for Damage and Looseness........................................... 419 BELTS......................................................................................... 420 Air Conditioner Compressor Belt........................................................... 420 Testing the Tension................................................................... 420 Adjusting the Tension................................................................. 420 Replacing Alternator Belt................................................................. 421 ACCELERATOR PEDAL............................................................................. 422 Testing Operating Effort.................................................................. 422 Testing Operating Angle................................................................... 423 DIRECTIONAL LEVER............................................................................. 424 Checking Operating Effort................................................................. 424 Checking Travel........................................................................... 424 POWER TRAIN OIL PRESSURES..................................................................... 425 HST Oil Pressure.......................................................................... 425 Testing High-Pressure Cutoff Oil Pressure............................................. 425 Testing Low-Pressure Relief Pressure.................................................. 426 Testing Servo Piston Control Pressure (DA Pressure)................................... 427 Testing Servo Piston Actuating Pressure............................................... 428 Adjusting High-Pressure Cutoff Valve.................................................. 428 Adjusting Low-Pressure Relief Valve................................................... 429 Adjusting DA Pressure................................................................. 430 Testing Clutch Control Pressure........................................................... 431 STEERING SYSTEM............................................................................... 433 Steering Wheel............................................................................ 433 Measuring Play........................................................................ 433 Measuring Operating Effort............................................................ 434 Measuring Operating Time.............................................................. 434 Steering Oil Pressure..................................................................... 435 Measuring Main Relief Pressure........................................................ 435 Adjusting Main Relief Pressure........................................................ 436 Bleeding Air from Steering Circuit........................................................ 437 HYDRAULIC DRIVE FAN........................................................................... 438 Measuring Fan Speed....................................................................... 438 Measuring Fan Drive Oil Pressure.......................................................... 439 WHEEL BRAKE SYSTEM............................................................................ 440 Measuring Pressing Angle of Brake Pedal................................................... 440 Brake Pedal Linkage....................................................................... 441 Testing............................................................................... 441 Adjusting............................................................................. 441 Measuring Brake Performance............................................................... 442 Accumulator Charge........................................................................ 443 Measuring............................................................................. 443 Adjusting............................................................................. 444 Measuring Brake Oil Pressure.............................................................. 445 Testing Wear of Wheel Brake Disc.......................................................... 448 Bleeding Air from Brake Circuit........................................................... 449 Releasing Residual Pressure in Brake Accumulator Circuit.................................. 450 PARKING BRAKE SYSTEM.......................................................................... 451 Testing Parking Brake Performance......................................................... 451 Parking Brake Control Cable............................................................... 452 Testing............................................................................... 452 Adjusting............................................................................. 452 WORK EQUIPMENT SYSTEM......................................................................... 453 Work Equipment Control Lever.............................................................. 453 Measuring Operating Effort............................................................ 453 Measuring Travel...................................................................... 453 Work Equipment Hydraulic Pressure......................................................... 454 Measuring............................................................................. 454 Adjusting............................................................................. 454 PPC Oil Pressure.......................................................................... 456 Measuring PPC Valve Basic Pressure.................................................... 456 Measuring PPC Valve Output Pressure................................................... 457 Bleeding Air from Hydraulic Circuit....................................................... 458 Bleeding Air from Work Equipment PPC Circuit.......................................... 458 Bleeding Air from Cylinders........................................................... 458 Releasing Residual Pressure in Hydraulic Circuit.......................................... 459 Between Each Hydraulic Cylinder and Control Valve..................................... 459 In Brake Accumulator Circuit.......................................................... 459 In PPC Accumulator Circuit............................................................ 459 Work Equipment Positioners................................................................ 460 Bucket Positioner..................................................................... 460 Boom Kickout Switch................................................................... 461 Proximity Switch Operation Pilot Lamp..................................................... 462 ELECTRICAL SYSTEM TROUBLESHOOTING............................................................. 463 Procedure for Testing Diodes.............................................................. 463 When Using Digital Type Circuit Tester................................................ 463 When Using Analog Type Circuit Tester................................................. 464 Preparation for Troubleshooting Electric System........................................... 465 Machine Monitor....................................................................... 465 HST Controller........................................................................ 466 KOMTRAX Terminal...................................................................... 467 Sensors................................................................................... 468 Boost Pressure and Temperature Sensor (BOOST PRESS & IMT)............................. 468 Supply Pump IMV Solenoid (FUEL REGULATOR)............................................. 468 Common Rail Pressure Sensor (FUEL RAIL PRESS)......................................... 469 Engine Coolant Temperature Sensor (COOLANT TEMP)...................................... 469 KOMTRAX TERMINAL SYSTEM....................................................................... 470 Terminal Installed at Plant Before Shipment............................................... 470 Terminal Retrofitted Machine After Shipment............................................... 470 Starting Operation........................................................................ 470 Application for the Start of Use...................................................... 473 Komtrax Terminal Lamps.................................................................... 474 Contents of 7-Segment and Dot Displays for CPU........................................ 476 MACHINE MONITOR SYSTEM........................................................................ 477 Adjusting Machine Monitor................................................................. 477 Adjusting for Replaced, Reassembled, or Added Sensor/Controller........................... 478 Adjustment for User’s Needs............................................................... 479 Special Functions of Machine Monitor (EMMS)............................................... 480 Normal and Special Functions of Machine Monitor....................................... 481 Functions and Flow of Service Mode........................................................ 482 Operator Mode............................................................................. 485 Service Meter Display Function (1).................................................... 485 Traction Level Selection Function (2)................................................. 485 HST Function Selection Function (3)................................................... 485 Odometer Display Function (4)......................................................... 486 Maintenance Monitoring Function (5)................................................... 486 Telephone Number Input Function (6)................................................... 486 Language Selection Function (7)....................................................... 486 Monitor Brightness Adjustment Function (8)............................................ 487 Travel Speed/Engine Speed Display Selecting Function (9).............................. 487 Travel Speed/Engine Speed Display/Non-Display Selecting Function (10)................. 488 Action Code Display Function (11)..................................................... 488 Failure Code Display Function (12).................................................... 489 Service Mode.............................................................................. 490 Switching to Service Mode and Screen Display (1)...................................... 490 Electrical System Fault History Display Function (ELECTRIC FAULT) (2)................. 492 Mechanical System Fault History Display Function (MACHINE FAULT) (3).................. 494 Real-Time Monitoring Function (REAL-TIME MONITOR) (4)................................. 495 Real-Time Monitoring Code Tables...................................................... 498 Engine Reduced-Cylinder Function (CYLINDER CUT-OUT) (5)............................... 512 No-Injection Cranking Function (6).................................................... 513 Adjustment Function (TUNING) (7)...................................................... 514 Maintenance Monitoring Function (8)................................................... 518 Operating Information Display Function (9)............................................ 524 Optional Device Selecting Function (10)............................................... 527 Machine Serial Number Input Function (11)............................................. 531 Model Select Function (MACHINE WA***) (12)............................................ 531 Initialize Function (13).............................................................. 532 Setting Procedure for Service Meter and Odometer...................................... 533 PM-CLINIC INSPECTION TABLE.................................................................... 537 40 TROUBLESHOOTING................................................................................ 541 POINTS TO REMEMBER WHEN TROUBLESHOOTING....................................................... 551 SEQUENCE OF EVENTS IN TROUBLESHOOTING......................................................... 553 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE..................................................... 554 Precautions when Handling Electrical Equipment............................................ 554 Handling Electronic Control Unit.......................................................... 559 Points to Remember When Troubleshooting Electrical Circuits............................... 560 Handling Hydraulic Equipment.............................................................. 561 ELECTRIC WIRE CODE............................................................................ 563 How to Read Electric Wire Code............................................................ 563 Type, Symbol, and Material................................................................ 563 Dimensions................................................................................ 564 Color Codes Table......................................................................... 565 Types of Circuits and Color Codes......................................................... 566 Classification by Thickness............................................................... 566 Classification by Color and Code.......................................................... 567 CHECKS BEFORE TROUBLESHOOTING................................................................. 568 Categories and Method of Using Troubleshooting Charts..................................... 569 Troubleshooting Individual Electrical Circuits............................................ 570 Chart Use............................................................................. 572 Chart Tips............................................................................ 572 Troubleshooting Individual Hydraulic Circuits............................................. 573 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS.................................................... 575 X-Type Connectors......................................................................... 575 SWP-Type Connectors....................................................................... 577 M-Type Connectors......................................................................... 579 S-Type Connectors......................................................................... 581 MIC-Type Connectors....................................................................... 583 AMP040-Type Connectors.................................................................... 585 AMP070-Type Connectors.................................................................... 587 Miscellaneous Types of Connectors......................................................... 589 HD30 Series Connectors.................................................................... 593 DT Series Connectors...................................................................... 598 DTM Series Connectors..................................................................... 600 DTHD Series Connectors.................................................................... 600 DTP Series Connectors..................................................................... 601 DRC26 Series Connectors................................................................... 602 DRC12, 16 Connectors...................................................................... 604 AMP Connectors for Pump Controller (CH700)................................................ 605 BOSCH Connectors for Engine............................................................... 607 SUMITOMO Connectors for Engine............................................................ 608 CANNON Connectors for Engine.............................................................. 609 AMP Connectors for Engine................................................................. 610 FRAMATOME Connectors for Engine........................................................... 611 PACKARD Connectors for Engine............................................................. 613 OT Series Connectors for Engine........................................................... 614 T-BRANCH BOX and T-BRANCH ADAPTER TABLE....................................................... 615 MODE CHART.................................................................................... 620 INFORMATION CONTAINED IN TESTING PROCEDURES................................................... 623 TROUBLESHOOTING BY FAILURE CODE............................................................... 625 Failure Code Table........................................................................ 625 FUSE BOX AND SLOW-BLOW FUSES.............................................................. 631 Connection Table of Fuse Box and Slow-Blow Fuses...................................... 631 Fuse Box: FS1..................................................................... 631 Fuse Box: FS2..................................................................... 632 Slow-Blow Fuses................................................................... 633 FAILURE CODES............................................................................. 634 2G40ZG................................................................................ 636 Brake: Oil Pressure Reduction..................................................... 636 6091NX................................................................................ 638 HST Filter: Clogging.............................................................. 638 989FN1................................................................................ 639 Travel Speed: Overrun Alarm....................................................... 639 AA1ANX................................................................................ 640 Air Cleaner: Clogging............................................................. 640 AB00L6................................................................................ 642 Alternator R System: Hot Short.................................................... 642 AB00MA................................................................................ 644 Alternator R System: Ground Fault/Disconnection/Low Charge Voltage................ 644 B@BAZG................................................................................ 646 Engine: Oil Pressure Reduction.................................................... 646 B@BAZK................................................................................ 647 Engine Oil: Low Level............................................................. 647 B@BCNS................................................................................ 648 Engine: Overheat.................................................................. 648 B@BCZK................................................................................ 650 Engine: Low Coolant Level......................................................... 650 B@C6NS................................................................................ 652 Front Brake: High Oil Temperature................................................. 652 B@CRNS................................................................................ 653 HST: High Oil Temperature......................................................... 653 CA111................................................................................. 654 Abnormality in Engine Controller.................................................. 654 CA115................................................................................. 655 Engine Ne or Bkup Speed Sensor Error.............................................. 655 CA122................................................................................. 656 Charge Pressure Sensor High Error................................................. 656 CA123................................................................................. 658 Charge Pressure Sensor Low Error.................................................. 658 CA131................................................................................. 660 Throttle Sensor High Error........................................................ 660 CA132................................................................................. 662 Throttle Sensor Low Error......................................................... 662 CA144................................................................................. 664 Coolant Sensor High Error......................................................... 664 CA145................................................................................. 666 Coolant Sensor Low error.......................................................... 666 CA153................................................................................. 668 Charge Temperature Sensor High Error.............................................. 668 CA154................................................................................. 670 Charge Temperature Sensor Low Error............................................... 670 CA155................................................................................. 672 Lowering of Speed by Abnormally High Charge Temperature........................... 672 CA187................................................................................. 674 Sensor Power Supply 2 Low Error................................................... 674 CA221................................................................................. 676 Atmospheric Pressure Sensor High Error............................................ 676 CA222................................................................................. 678 Atmospheric Sensor Low Error...................................................... 678 CA227................................................................................. 680 Sensor Power Supply 2 High Error.................................................. 680 CA234................................................................................. 682 Engine Overspeed.................................................................. 682 CA238................................................................................. 683 Ne Speed Sensor Power Supply Error................................................ 683 CA271................................................................................. 684 IMV (IMA) Short Circuit........................................................... 684 CA272................................................................................. 686 IMV (IMA) Disconnection........................................................... 686 CA322................................................................................. 688 Injector #1 Open/Short Error...................................................... 688 CA323................................................................................. 690 Injector #5 Open/Short Error...................................................... 690 CA324................................................................................. 692 Injector #3 Open/Short Error...................................................... 692 CA325................................................................................. 694 Injector #6 Open/Short Error...................................................... 694 CA331................................................................................. 696 Injector #2 Open/Short Error...................................................... 696 CA332................................................................................. 698 Injector #4 Open/Short Error...................................................... 698 CA342................................................................................. 700 Calibration Code Inconsistency.................................................... 700 CA351................................................................................. 702 Injectors Drive Circuit Error..................................................... 702 CA352................................................................................. 704 Sensor Power Supply 1 Low Error................................................... 704 CA386................................................................................. 706 Sensor Power Supply 1 High Error.................................................. 706 CA428................................................................................. 708 Abnormally High Level in Water Sensor............................................. 708 CA429................................................................................. 710 Abnormally Low Level in Water Sensor.............................................. 710 CA431................................................................................. 712 Idle Validation Switch Error...................................................... 712 CA432................................................................................. 716 Idle Validation Action Error...................................................... 716 CA435................................................................................. 720 Engine Oil Pressure Switch Error.................................................. 720 CA441................................................................................. 722 Battery Voltage Low Error......................................................... 722 CA442................................................................................. 726 Battery Voltage High Error........................................................ 726 CA449................................................................................. 728 Common Rail Pressure High Error 2................................................. 728 CA451................................................................................. 730 Common Rail Pressure Sensor High Error............................................ 730 CA452................................................................................. 732 Common Rail Pressure Sensor Low Error............................................. 732 CA488................................................................................. 734 Lowering of Torque by Abnormally High Charge Temperature.......................... 734 CA553................................................................................. 735 Common Rail Pressure High Error 1................................................. 735 CA559................................................................................. 736 Supply Pump Pressure Very Low Error............................................... 736 CA689................................................................................. 738 Engine Ne Speed Sensor Error...................................................... 738 CA731................................................................................. 740 Engine Bkup Speed Sensor Phase Error.............................................. 740 CA757................................................................................. 741 All Continuous Data Lost Error.................................................... 741 CA778................................................................................. 744 Engine Bkup Speed Sensor Error.................................................... 744 CA1633................................................................................ 746 KOMNET Datalink Timeout Error..................................................... 746 CA2185................................................................................ 750 Throttle Sensor Supply Voltage High Error......................................... 750 CA2186................................................................................ 752 Throttle Sensor Power Supply Low Error............................................ 752 CA2249................................................................................ 754 Supply Pump Pressure Very Low Error 2............................................. 754 CA2311................................................................................ 756 Abnormality in IMV (IMA) Solenoid................................................. 756 CA2555................................................................................ 758 Intake Heater Relay Disconnection Error........................................... 758 CA2556................................................................................ 760 Intake Heater Relay Short Circuit Error........................................... 760 D160KY................................................................................ 762 Backup Alarm/Lamp Relay 1 Circuit: Hot Short...................................... 762 D192KY................................................................................ 764 ECSS Solenoid Relay: Hot Short.................................................... 764 D1B0KA................................................................................ 766 HST Safety Relay: Disconnection................................................... 766 D1B0KB................................................................................ 768 HST Safety Relay: Ground Fault.................................................... 768 D1B0KY................................................................................ 770 HST Safety Relay: Hot Short....................................................... 770 D5ZHL6................................................................................ 772 IGN C System: Ground Fault/Disconnection.......................................... 772 DAF3KK................................................................................ 774 UNSW Power Supply: Ground Fault/Disconnection..................................... 774 DAFRKR................................................................................ 776 Machine Monitor CAN-NET Signal: Disconnection..................................... 776 DAJ0KK................................................................................ 778 HST Controller Power Supply: Low Voltage.......................................... 778 DAJ0KT................................................................................ 780 HST Controller Memory (EEPROM): Abnormality....................................... 780 DAJ1L4................................................................................ 782 HST Controller Main Power Line: Disconnection/Ground Fault........................ 782 DAJ1L6................................................................................ 784 HST Controller Main Power Line: Hot Short......................................... 784 DAJ2KK................................................................................ 786 Controller Solenoid Power Supply: Low Voltage..................................... 786 DAJ2L3................................................................................ 788 HST Controller Load Power Supply Holding Line: Hot Short in Wiring Harness........ 788 DAJ2L4................................................................................ 790 HST Controller Load Power Supply Holding Line: Disconnection/Ground Fault......... 790 DAJ5KX................................................................................ 792 Sensor 5V Power Supply: Out-of-Output Range....................................... 792 DAJ9KQ................................................................................ 794 HST Controller Model Selection: Disagreement of Model Selection Signals........... 794 DAJRKR................................................................................ 796 HST Controller CAN-NET Signal: Disconnection...................................... 796 DAJRMA................................................................................ 801 HST Controller: Disagreement in Option Selection.................................. 801 DB2RKR................................................................................ 802 Engine Controller CAN-NET: Disconnection in Signal Line........................... 802 DD1NL4................................................................................ 808 Fan Automatic Reverse Switch Signal: Abnormality.................................. 808 DD1NLD................................................................................ 810 Fan Reverse Switch Signal: Abnormality............................................ 810 DDB6KA................................................................................ 812 Parking Brake Reminder Signal: Disconnection/Short Circuit........................ 812 DDB6KB................................................................................ 814 Parking Brake Indicator Signal: Ground Fault...................................... 814 DDB6KZ................................................................................ 816 Parking Brake Switch or Parking Brake Reminder Switch: Trouble.................... 816 DDB6L0................................................................................ 818 Parking Brake Reminder Signal: Ground Fault....................................... 818 DDB6L4................................................................................ 820 Parking Brake Indicator Signal: Disconnection/Hot Short........................... 820 DDD7KX................................................................................ 822 Travel Speed Control Dial Signal: Disconnection/Ground Fault...................... 822 DDD7KY................................................................................ 824 Travel Speed Control Dial Signal: Hot Short....................................... 824 DDE5MA................................................................................ 826 Emergency Steering Operation Switch: Disconnection................................ 826 DDK3KA................................................................................ 828 Directional Selector Switch: Disconnection/Hot Short.............................. 828 DDK3KB................................................................................ 830 Directional Selector Switch: Ground Fault......................................... 830 DDK6KA................................................................................ 832 FNR Lever: Disconnection/Ground Fault............................................. 832 DDK6KY................................................................................ 836 FNR Lever: Hot Short.............................................................. 836 DDS5L6................................................................................ 838 Steering: Low Oil Pressure (Operation of Emergency Steering)...................... 838 DF10KA................................................................................ 840 Travel Speed Range Selector Switch: Disconnection/Ground Fault.................... 840 DF10KB................................................................................ 844 Travel Speed Range Selector Switch: Hot Short..................................... 844 DGH1KX................................................................................ 846 HST Oil Temperature Sensor: Ground Fault.......................................... 846 DGR2KB................................................................................ 848 Brake Oil Temperature Sensor: Ground Fault........................................ 848 DGR2KZ................................................................................ 850 Brake Oil Temperature Sensor: Disconnection/Hot Short............................. 850 DHH1KX................................................................................ 852 HST Oil Pressure Sensor: Disconnection/Ground Fault............................... 852 DHH1KY................................................................................ 854 HST Oil Pressure Sensor: Hot Short................................................ 854 DHTCL6................................................................................ 856 HST Filter Clogging Sensor: Functional Defect..................................... 856 DJF1KA................................................................................ 858 Fuel Level Sensor: Disconnection/Hot Short........................................ 858 DLT3KX................................................................................ 860 Travel Speed Sensor B: Abnormality................................................ 860 DLT4KX................................................................................ 864 Travel Speed Sensor A: Abnormality................................................ 864 DLT4LC................................................................................ 866 Travel Speed Sensor A & B: Abnormality............................................ 866 DV00KY................................................................................ 868 Alarm Buzzer: Hot Short........................................................... 868 DW26KA................................................................................ 870 Motor 2 Solenoid: Disconnection/Ground Fault...................................... 870 DW26KY................................................................................ 872 Motor 2 Solenoid: Hot Short....................................................... 872 DW7BKY................................................................................ 874 Fan Reverse Solenoid Circuit: Hot Short........................................... 874 DW7BKZ................................................................................ 876 Fan Reverse Solenoid Circuit: Disconnection/Ground Fault.......................... 876 DX16KA................................................................................ 878 Fan EPC Solenoid: Disconnection................................................... 878 DX16KB................................................................................ 880 Fan EPC Solenoid: Ground Fault.................................................... 880 DX16KY................................................................................ 882 Fan EPC Solenoid: Hot Short....................................................... 882 DX19KA................................................................................ 884 Motor 1 Solenoid: Disconnection................................................... 884 DX19KB................................................................................ 886 Motor 1 Solenoid: Ground Fault.................................................... 886 DX19KY................................................................................ 888 Motor 1 Solenoid: Hot Short....................................................... 888 DX20KA................................................................................ 890 Clutch EPC Solenoid: Disconnection................................................ 890 DX20KB................................................................................ 892 Clutch EPC Solenoid: Ground Fault................................................. 892 DX20KY................................................................................ 894 Clutch EPC Solenoid: Hot Short.................................................... 894 DXH7KB................................................................................ 896 Reverse Solenoid: Ground Fault.................................................... 896 DXH7KZ................................................................................ 898 Reverse Solenoid: Disconnection/Hot Short......................................... 898 DXH8KB................................................................................ 900 Forward Solenoid: Ground Fault.................................................... 900 DXH8KZ................................................................................ 902 Forward Solenoid: Disconnection/Hot Short......................................... 902 J141N1................................................................................ 904 Steering Pump: Overrun Alarm...................................................... 904 M100N1................................................................................ 905 HST Pump: Overrun Alarm........................................................... 905 M400N1................................................................................ 906 Motor 1: Overrun Alarm............................................................ 906 TROUBLESHOOTING: E-MODE................................................................... 908 Troubleshooting Electrical System..................................................... 908 Information in Troubleshooting Table.............................................. 908 E-1................................................................................... 910 Engine Does Not Start............................................................. 910 E-2................................................................................... 918 Preheater Does Not Operate Manually............................................... 918 E-3................................................................................... 922 Travel Speed is Low or High....................................................... 922 E-4................................................................................... 928 ECSS Does Not Operate............................................................. 928 E-5................................................................................... 931 ECSS Keeps Operating.............................................................. 931 E-6................................................................................... 934 Defective Boom Kickout Function and Cancellation.................................. 934 E-7................................................................................... 938 Defective Bucket Positioner Function and Cancellation............................. 938 E-8................................................................................... 942 Defective Lift Arm FLOATING Holding Function and Cancellation..................... 942 E-9................................................................................... 946 Travel Direction Selection System Does Not Function............................... 946 E-10.................................................................................. 950 Fan Does Not Reverse.............................................................. 950 E-11.................................................................................. 954 Fan Keeps Rotating in Reverse..................................................... 954 E-12.................................................................................. 956 Wiper Does Not Operate............................................................ 956 E-13.................................................................................. 960 Windshield Washer Does Not Operate................................................ 960 E-14.................................................................................. 963 Headlamp, Clearance Lamp, and Tail Lamp Do Not Light Up or Go Off................. 963 E-15.................................................................................. 971 Working Lamp Does Not Light Up or Go Off.......................................... 971 E-16.................................................................................. 976 Turn Signal Lamp and Hazard Lamp Do Not Light Up or Go Off........................ 976 E-17.................................................................................. 982 Brake Lamp Does Not Light or It Keeps Lighting Up................................. 982 E-18.................................................................................. 984 Backup Lamp Does Not Light or It Keeps Lighting Up................................ 984 E-19.................................................................................. 987 Backup Alarm Does Not Sound or It Keeps Sounding.................................. 987 E-20.................................................................................. 990 Horn Does Not Sound or It Keeps Sounding.......................................... 990 E-21.................................................................................. 992 Alarm Buzzer Does Not Sound or It Keeps Sounding.................................. 992 E-22.................................................................................. 994 Air Conditioner Does Not Operate or Stop.......................................... 994 E-23.................................................................................. 997 The KOMTRAX System Does Not Work Properly......................................... 997 Lamp Display Section of KOMTRAX Terminal...................................... 999 TROUBLESHOOTING: H-MODE...................................................................1000 Troubleshooting Hydraulic and Mechanical Systems......................................1000 Method of Using Troubleshooting Chart.............................................1000 Table of Failure Codes and Causes.....................................................1002 H-1...................................................................................1004 Machine Does Not Start............................................................1004 H-2...................................................................................1005 Travel Speed Is Slow..............................................................1005 H-3...................................................................................1006 Traction Force Is Weak............................................................1006 H-4...................................................................................1007 Engine Stalls When Traveling or Engine Speed Drops Excessively....................1007 H-5...................................................................................1008 Shift Range is Not Shifted........................................................1008 H-6...................................................................................1009 Steering Wheel Does Not Turn......................................................1009 H-7...................................................................................1010 Steering Wheel is Heavy...........................................................1010 H-8...................................................................................1011 Steering Wheel Shakes or Jerks....................................................1011 H-9...................................................................................1012 Machine Deviates Naturally to One Side When Traveling.............................1012 H-10..................................................................................1013 Brake Does Not Work or Does Not Work Well.........................................1013 H-11..................................................................................1014 Brake Is Not Released or Is Dragged...............................................1014 H-12..................................................................................1015 Lift Arm Does Not Rise or Lower...................................................1015 H-13..................................................................................1016 Lift Arm Moves Slowly or Lift Arm Rising Force Is Insufficient....................1016 H-14..................................................................................1017 When Rising, Lift Arm Starts to Move Slowly at a Specific Height..................1017 H-15..................................................................................1017 Lift Arm Cylinder Cannot Hold Down The Bucket (Bucket Rises in the Air)...........1017 H-16..................................................................................1017 Hydraulic Drifts of the Lift Arm Occur Often......................................1017 H-17..................................................................................1018 Lift Arm Wobbles During Operation.................................................1018 H-18..................................................................................1018 When Control Lever Is Switched from HOLD to RAISE, Lift Arm Falls Temporarily.....1018 H-19..................................................................................1019 Bucket Does Not Tilt Back.........................................................1019 H-20..................................................................................1020 Bucket Moves Slowly or Tilting-Back Force Is Insufficient.........................1020 H-21..................................................................................1021 Bucket Starts to Operate Slowly in the Midst of Tilting Back......................1021 H-22..................................................................................1021 Bucket Cylinder Cannot Hold Down the Bucket.......................................1021 H-23..................................................................................1021 Hydraulic Drifts of the Bucket Occur Often........................................1021 H-24..................................................................................1022 Bucket Wobbles During Travel with Load............................................1022 H-25..................................................................................1022 When Control Lever Is Switched from HOLD to TILT, the Bucket Falls Temporarily....1022 H-26..................................................................................1023 Control Levers of Lift Arm and Bucket Do Not Move Smoothly and Are Heavy..........1023 H-27..................................................................................1024 ECSS Does Not Operate and Machine Pitches and Bounces.............................1024 H-28..................................................................................1025 Fan Revolution Is Abnormal........................................................1025 50 DISASSEMBLY AND ASSEMBLY.......................................................................1027 HOW TO READ THIS MANUAL.......................................................................1031 Removal and Installation of Assemblies....................................................1031 Disassembly and Assembly of Assemblies....................................................1033 COATING MATERIALS LIST........................................................................1035 SPECIAL TOOLS LIST............................................................................1039 SKETCHES OF SPECIAL TOOLS.....................................................................1043 CONNECTOR REPAIR PROCEDURES...................................................................1050 Stripping Insulation......................................................................1050 Wire Inspection...........................................................................1050 Contact Terminal Removal (HD30 Type)......................................................1051 Crimping Contact Terminal (HD30 Type).....................................................1052 Insertion Of Contact Terminal (HD30 Type).................................................1053 Contact Terminal Removal (DT Type)........................................................1054 Crimping Contact Terminal (DT Type).......................................................1055 Insertion Of Contact Terminal (DT Type)...................................................1056 ENGINE AND COOLING SYSTEM.....................................................................1057 Fuel Supply Pump Assembly.................................................................1057 Removal...............................................................................1057 Installation..........................................................................1059 Fuel Injector Assembly....................................................................1060 Removal...............................................................................1060 Installation..........................................................................1065 Cylinder Head Assembly....................................................................1069 Removal...............................................................................1069 Installation..........................................................................1078 Engine Hood Assembly......................................................................1084 Removal...............................................................................1084 Installation..........................................................................1087 Radiator..................................................................................1088 Removal...............................................................................1088 Installation..........................................................................1091 Air Aftercooler...........................................................................1092 Removal...............................................................................1092 Installation..........................................................................1093 Hydraulic Oil Cooler Assembly.............................................................1094 Removal...............................................................................1094 Installation..........................................................................1096 Engine Assembly...........................................................................1097 Removal...............................................................................1097 Installation..........................................................................1103 Engine Front Oil Seal Assembly............................................................1105 Removal...............................................................................1105 Installation..........................................................................1107 Engine Rear Oil Seal Assembly.............................................................1108 Removal...............................................................................1108 Installation..........................................................................1110 Cooling Fan and Fan Motor Assembly........................................................1113 Removal...............................................................................1113 Installation..........................................................................1116 Fuel Tank Assembly........................................................................1117 Removal...............................................................................1117 Installation..........................................................................1119 POWER TRAIN...................................................................................1120 Transfer Case Assembly....................................................................1120 Removal...............................................................................1120 Installation..........................................................................1123 Transfer Assembly.........................................................................1125 Disassembly...........................................................................1126 Assembly..............................................................................1137 Parking Brake Assembly....................................................................1150 Removal...............................................................................1150 Installation..........................................................................1151 Disassembly...........................................................................1152 Assembly..............................................................................1155 Front Axle Assembly.......................................................................1159 Removal...............................................................................1159 Installation..........................................................................1161 Rear Axle Assembly........................................................................1162 Removal...............................................................................1162 Installation..........................................................................1165 Axle Housing Assembly.....................................................................1166 Disassembly...........................................................................1167 Assembly..............................................................................1173 Differential Assembly.....................................................................1182 Disassembly...........................................................................1183 Assembly..............................................................................1195 UNDERCARRIAGE AND FRAME.......................................................................1213 Center Hinge Pin..........................................................................1213 Removal...............................................................................1213 Installation..........................................................................1220 Counterweight.............................................................................1226 Removal...............................................................................1226 Installation..........................................................................1227 HYDRAULIC SYSTEM..............................................................................1228 HST Pump and 4-Gear Pump Assembly.........................................................1228 Removal...............................................................................1228 Installation..........................................................................1231 HST Pump Assembly.........................................................................1233 Disassembly...........................................................................1233 Assembly..............................................................................1246 HST Motor 1 Assembly......................................................................1266 Removal...............................................................................1266 Installation..........................................................................1267 HST Motor 2 Assembly......................................................................1268 Removal...............................................................................1268 Installation..........................................................................1269 HST Motor Assembly........................................................................1270 Disassembly...........................................................................1270 Assembly..............................................................................1282 Work Equipment Control Valve Assembly.....................................................1292 Removal...............................................................................1292 Installation..........................................................................1294 Hydraulic Tank Assembly...................................................................1295 Removal...............................................................................1295 Installation..........................................................................1297 Hydraulic Cylinder Assembly...............................................................1298 Disassembly...........................................................................1299 Assembly..............................................................................1302 WORK EQUIPMENT................................................................................1306 Work Equipment Assembly...................................................................1306 Removal...............................................................................1306 Installation..........................................................................1310 CAB AND ITS ATTACHMENTS.......................................................................1315 Operator’s Cab and Floor Frame Assembly...................................................1315 Removal...............................................................................1315 Installation..........................................................................1320 Operator’s Cab Glass (Stuck Glass)........................................................1322 Removal...............................................................................1322 Installation..........................................................................1323 Operator’s Seat Assembly..................................................................1331 Disassembly...........................................................................1332 Assembly..............................................................................1339 Air Conditioner Unit......................................................................1344 Removal...............................................................................1344 Installation..........................................................................1349 ELECTRICAL SYSTEM.............................................................................1350 Monitor Panel.............................................................................1350 Removal...............................................................................1350 Installation..........................................................................1352 Engine Controller Assembly................................................................1353 Removal...............................................................................1353 Installation..........................................................................1354 HST Controller Assembly...................................................................1355 Removal...............................................................................1355 Installation..........................................................................1355 KOMTRAX Terminal Assembly.................................................................1356 Removal...............................................................................1356 Installation..........................................................................1357 WASTE HANDLER GUARDS..........................................................................1358 Hydraulic Tank Guard......................................................................1358 Removal...............................................................................1358 Installation..........................................................................1360 Rear Light Guards.........................................................................1361 Removal...............................................................................1361 Installation..........................................................................1361 Front Light Guards........................................................................1362 Removal...............................................................................1362 Installation..........................................................................1362 Front Step................................................................................1363 Removal...............................................................................1363 Installation..........................................................................1363 Axle Seal Guards..........................................................................1364 Removal...............................................................................1364 Installation..........................................................................1364 Boom Cylinder Hose Guards.................................................................1365 Removal...............................................................................1365 Installation..........................................................................1365 Front Frame Underguard....................................................................1366 Removal...............................................................................1366 Installation..........................................................................1366 Fuel Tank Guard...........................................................................1367 Removal...............................................................................1367 Installation..........................................................................1368 Rear Frame Underguard.....................................................................1369 Removal...............................................................................1369 Installation..........................................................................1369 WASTE HANDLER SCREENS.........................................................................1371 Lower Engine Baffle.......................................................................1371 Removal...............................................................................1371 Installation..........................................................................1371 Hood Screen...............................................................................1372 Removal...............................................................................1372 Installation..........................................................................1372 Exhaust Cover.............................................................................1373 Removal...............................................................................1373 Installation..........................................................................1373 90 DIAGRAMS AND SCHEMATICS........................................................................1375 AUTOMATIC GREASING CIRCUIT DIAGRAM............................................................1377 HYDRAULIC SYSTEM..............................................................................1379 HYDRAULIC CIRCUIT DIAGRAM.................................................................1379 ELECTRICAL SYSTEM.............................................................................1380 ELECTRICAL CIRCUIT DIAGRAM (1/9)..........................................................1380 ELECTRICAL CIRCUIT DIAGRAM (2/9)..........................................................1381 ELECTRICAL CIRCUIT DIAGRAM (3/9)..........................................................1382 ELECTRICAL CIRCUIT DIAGRAM (4/9)..........................................................1383 ELECTRICAL CIRCUIT DIAGRAM (5/9)..........................................................1384 ELECTRICAL CIRCUIT DIAGRAM (6/9)..........................................................1385 ELECTRICAL CIRCUIT DIAGRAM (7/9)..........................................................1386 ELECTRICAL CIRCUIT DIAGRAM (8/9)..........................................................1387 ELECTRICAL CIRCUIT DIAGRAM (9/9)..........................................................1388 ELECTRICAL CIRCUIT DIAGRAM (1/3)..........................................................1389 ELECTRICAL CIRCUIT DIAGRAM (2/3)..........................................................1390 ELECTRICAL CIRCUIT DIAGRAM (3/3)..........................................................1391
KOMATSU WA320-6 WHEEL LOADER SHOP MANUAL – PDF DOWNLOAD:
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