Komatsu WA320-6 WA320PZ-6 Wheel Loader Workshop Repair Service Manual PDF - MKMTSWA320PZ.zip
A full factory-style service and repair guide featuring Electrical Wiring Diagrams for the Komatsu WA320 and WA320PZ Wheel Loaders, containing every technical detail needed to service, troubleshoot, fix, and rebuild these machines the way trained technicians do.
The Komatsu WA320 and WA320PZ Wheel Loader workshop service and repair manual covers:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEN03911-03 - Wheel Loader WA320-6, WA320PZ-6 Shop Manual.pdf
SEN03911-04 - Wheel Loader WA320-6, WA320PZ-6 Shop Manual.pdf
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VEBM620100 - Wheel Loader WA320-6, WA320-PZ6 Shop Manual.pdf
TEN00265-04 - Wheel Loader WA320PZ-6 Operation & Maintenance Manual.pdf
TEN00410-00 - Wheel Loader WA320PZ-6 Operation & Maintenance Manual.pdf
TEN00459-01 - Wheel Loader WA320PZ-6 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 6,032 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
SEN03911-03 - Wheel Loader WA320-6, WA320PZ-6 Shop Manual....1
COVER....1
00 Index and foreword....0
100 Index....2
Composition of shop manual....3
Table of contents....5
200 Foreword and general information....16
Safety notice....17
How to read the shop manual....22
Explanation of terms for maintenance standard....24
Handling of electric equipment and hydraulic component....26
Handling of connectors newly used for engines....35
How to read electric wire code....38
Precautions when carrying out operation....41
Method of disassembling and connecting push-pull type coupler....44
Standard tightening torque table....47
Conversion table....51
01 Specification....0
100 Specification and technical data....58
Specification dimension drawing....60
Specifications....61
Weight table....65
Table of fuel, coolant and lubricants....67
10 Structure, function and maintenance standard....0
100 Engine and cooling system....70
Engine mount and transfer mount....71
Damper....72
Cooling system....73
Cooling system hydraulic piping diagram....74
Cooling fan motor....76
200 Power train....86
Power train....88
Power train system diagram....89
Drive shaft....91
HST hydraulic piping diagram....92
HST pump....93
HST motor....101
Transfer....107
Clutch solenoid valve....118
Axle....119
Differential....121
Torque proportioning differential....126
Limited slip differential....129
Final drive....133
300 Steering system....138
Steering piping diagram....140
Steering column....141
Priority valve....142
Orbit-roll valve....145
Cushion valve....153
Steering cylinder....154
Emergency steering piping diagram....156
Emergency steering valve....157
Steering relief valve....160
400 Brake system....162
Brake piping diagram....164
Charge valve....165
Brake valve....169
Inching valve....173
Accumulator (for brake)....174
Slack adjuster....175
Brake....177
Parking brake control....182
Parking brake....183
500 Undercarriage and frame....186
Axle mount and center hinge pin....187
Tires....192
600 Hydraulic system....194
Work equipment hydraulic piping diagram....195
Work equipment control lever linkage....199
Hydraulic tank....203
4-gear pump....205
Work equipment control valve....207
Cut-off valve....233
PPC valve....236
Lock valve....251
Accumulator (for PPC circuit)....252
ECSS valve....254
Accumulator (for ECSS)....256
700 Work equipment....258
Work equipment linkage....259
Bucket....263
Bucket positioner and boom kick-out....267
Work equipment cylinder....279
800 Cab and its attachments....282
Cab....284
Air conditioner....285
910 Electrical system, Part 1....298
Machine monitor system....299
Machine monitor....303
920 Electrical system, Part 2....326
Electrical system (HST controller system)....327
HST controller....343
ECSS system....345
KOMTRAX system....347
Engine starting circuit....349
Engine stopping circuit....351
Preheating circuit....352
Engine output derating function....353
Automatic warm-up function....353
Parking brake circuit....355
Coupler plunger control system....357
Multi-function knob....358
Max. traction switch....359
Sensor....360
20 Standard value table....0
100 Standard service value table....368
Standard service value table for engine....369
Standard service value table for chassis....370
30 Testing and adjusting....0
110 Testing and adjusting, Part 1....378
Tools for testing, adjusting, and troubleshooting....380
Measuring engine speed....385
Measuring exhaust gas color....387
Adjusting valve clearance....389
Measuring compression pressure....391
Measuring blow-by pressure....394
Measuring engine oil pressure....395
Measuring intake air (boost) pressure....396
Handling fuel system equipment....398
Releasing residual pressure in fuel system....398
Measuring fuel pressure....399
Measuring fuel return rate and leakage....401
Bleeding air from fuel circuit....405
Checking leakage in fuel system....406
Handling cylinder cut-out mode operation....407
Handling no-injection cranking operation....407
Handling controller voltage circuit....408
Check of muffler and muffler stack for looseness and damage....408
Check of muffler function....409
Check of installed condition of cylinder head and manifolds....409
Check of engine piping for damage and looseness....410
Testing and adjusting air conditioner compressor belt tension....410
Replacing alternator belt....411
120 Testing and adjusting, Part 2....414
Checking operating force of accelerator pedal....416
Checking directional lever....417
Testing and adjusting HST oil pressure....418
Testing clutch control pressure....422
Testing and adjusting steering wheel....423
Testing and adjusting steering oil pressure....425
Bleeding air from steering circuit....427
Testing hydraulic fan....428
Measuring brake pedal....430
Testing and adjusting brake pedal linkage....431
Measuring brake performance....432
Testing and adjusting accumulator charge pressure....433
Testing wheel brake oil pressure....435
Testing wear of brake disc....438
Bleeding air from wheel brake circuit....439
Releasing residual pressure in brake accumulator circuit....440
Testing parking brake performance....441
Testing and adjusting parking brake control cable....442
Measuring and adjusting work equipment control lever....443
Testing and adjusting worke quipment hydraulic pressure....444
Testing work equipment PPC oil pressure....445
Bleeding air from hydraulic circuit....447
Releasing remaining pressure in hydraulic circuit....448
Testing and adjusting bucket positioner....449
Testing and adjusting of boom kick-out switch....450
Checking proximity switch operation pilot lamp....451
Procedure for testing diodes....452
Preparation work for troubleshooting for electric system....453
Starting KOMTRAX terminal operations....457
Indicator lamps of KOMTRAX terminal....461
130 Testing and adjusting, Part 3....466
Adjusting machine monitor....467
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor....468
Special functions of machine monitor (EMMS)....470
Pm clinic inspection chart....525
40 Troubleshooting....0
100 Failure code table and fuse locations....528
Failure codes table....529
Fuse locations....535
200 General information on troubleshooting....540
Points to remember when troubleshooting....541
Sequence of events in troubleshooting....542
Testing before troubleshooting....543
Classification and procedures of troubleshooting....544
Information contained in troubleshooting table....547
Connection table for connector pin numbers....549
T- branch box and T- branch adapter table....585
310 Troubleshooting by failure code (Display of code), Part 1....590
Failure code [2G40ZG] Brake: Oil pressure reduction....591
Failure code [6091NX] HST filter: Clogging....593
Failure code [989FN1] Travel speed: Overrun alarm....595
Failure code [AA1ANX] Air cleaner: Clogging....597
Failure code [AB00L6] Alternator R system: Hot short....599
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage....601
Failure code [B@BAZG] Engine: Oil pressure reduction....603
Failure code [B@BAZK] Engine oil: Low level....604
Failure code [B@BCNS] Engine: Overheat....605
Failure code [B@BCZK] Engine: Low coolant level....607
Failure code [B@C6NS] Front brake: High oil temperature....609
Failure code [B@CRNS] HST: High oil temperature....610
320 Troubleshooting by failure code (Display of code), Part 2....612
Failure code [CA111] Abnormality in engine controller....614
Failure code [CA115] Engine Ne or Bkup speed sensor error....615
Failure code [CA122] Charge pressure sensor high error....617
Failure code [CA123] Charge pressure sensor low error....619
Failure code [CA131] Throttle sensor high error....621
Failure code [CA132] Throttle sensor low error....623
Failure code [CA144] Coolant sensor high error....625
Failure code [CA145] Coolant sensor low error....627
Failure code [CA153] Charge temperature sensor high error....629
Failure code [CA154] Charge temperature sensor low error....631
Failure code [CA155] Derating of speed by abnormally high charge temperature....633
Failure code [CA187] Sensor power supply 2 low error....635
Failure code [CA221] Atmospheric pressure sensor high error....637
Failure code [CA222] Atmospheric sensor low error....639
Failure code [CA227] Sensor power supply 2 high error....641
Failure code [CA234] Engine overspeed....642
Failure code [CA238] Ne speed sensor power supply error....643
Failure code [CA271] IMV (IMA) Short circuit....644
Failure code [CA272] IMV (IMA) Disconnection....645
Failure code [CA322] Injector #1 open/short error....647
Failure code [CA323] Injector #5 open/short error....649
Failure code [CA324] Injector #3 open/short error....651
Failure code [CA325] Injector #6 open/short error....653
Failure code [CA331] Injector #2 open/short error....655
Failure code [CA332] Injector #4 open/short error....657
Failure code [CA342] Calibration code inconsistency....659
Failure code [CA351] Injectors drive circuit error....661
Failure code [CA352] Sensor power supply 1 low error....663
Failure code [CA386] Sensor power supply 1 high error....665
330 Troubleshooting by failure code (Display of code), Part 3....668
Failure code [CA428] Abnormally high level in water sensor....671
Failure code [CA429] Abnormally low level in water sensor....673
Failure code [CA431] Idle validation switch error....675
Failure code [CA432] Idle validation action error....679
Failure code [CA435] Engine oil pressure switch error....683
Failure code [CA441] Battery voltage low error....684
Failure code [CA442] Battery voltage high error....687
Failure code [CA449] Common rail pressure high error 2....689
Failure code [CA451] Common rail pressure sensor high error....691
Failure code [CA452] Common rail pressure sensor low error....693
Failure code [CA488] Derating of torque by abnormally high charge temperature....695
Failure code [CA553] Common rail pressure high error 1....696
Failure code [CA559] Supply pump pressure very low error....697
Failure code [CA689] Engine Ne speed sensor error....699
Failure code [CA731] Engine Bkup speed sensor phase error....701
Failure code [CA757] All continuous data lost error....702
Failure code [CA778] Engine Bkup speed sensor error....705
Failure code [CA1633] KOMNET datalink timeout error....707
Failure code [CA2185] Throttle sensor supply voltage high error....711
Failure code [CA2186] Throttle sensor power supply low error....713
Failure code [CA2249] Supply pump pressure very low error 2....715
Failure code [CA2311] Abnormality in IMV (IMA) solenoid....717
Failure code [CA2555] Intake heater relay disconnection error....719
Failure code [CA2556] Intake heater relay short circuit error....721
340 Troubleshooting by failure code (Display of code), Part 4....724
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short....725
Failure code [D192KY] ECSS solenoid relay: Hot short....727
Failure code [D1B0KA] HST safety relay: Disconnection....729
Failure code [D1B0KB] HST safety relay: Ground fault....731
Failure code [D1B0KY] HST safety relay: Hot short....733
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection....735
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection....737
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection....739
Failure code [DAJ0KK] HST controller power supply: Low voltage....743
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality....745
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault....747
Failure code [DAJ1L6] HST controller main power line: Hot short....749
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage....751
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness....753
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault....755
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range....757
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals....759
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection....760
Failure code [DAJRMA] HST controller: Disagreement in option selection....766
350 Troubleshooting by failure code (Display of code), Part 5....768
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line....769
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality....775
Failure code [DD1NLD] Fan reverse switch signal: Abnormality....777
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short....779
Failure code [DDB6KB] Parking brake indicator signal: Ground fault....781
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble....783
Failure code [DDB6L0] Parking brake reminder signal: Ground fault....785