Free Komatsu Wheel Loader WA320-7 USA sn:A36001 and up Workshop Service Manual Download

Original Illustrated Factory Workshop Service Manual for Komatsu Wheel Loader WA320.



Original factory manuals for Komatsu Loaders, Dozers, Excavators contains high quality images, circuit diagrams and instructions to help you to operate, maintenance and repair your truck. All Manuals Printable, contains Searchable Text and Navigation Bookmarks



Covered models:

WA320-7 USA sn:A36001 and up



Format: PDF, 2039 Pages

Language: English



Contents:

00 Index and foreword .

Index

Foreword, safety and general information

Important safety notice

How to read the shop manual

Explanation of terms for maintenance standard

Handling equipment of fuel system devices

Handling of intake system parts

Handling of hydraulic equipment

Method of disconnecting and connecting of push-pull type coupler

Handling of electrical equipment

How to read electric wire code

Precautions when performing operation

Practical use of KOMTRAX

Standard tightening torque table

List of abbreviation

Conversion table

01 Specification.

Table of contents

Specifications

Specification drawing

Specifications

Weight table

Table of fuel, coolant, and lubricants

10 Structure and function .

Table of contents

Engine and cooling system

Engine related parts

KVGT

EGR system piping drawing

EGR system circuit diagram

EGR valve

EGR cooler

KCCV layout drawing

KCCV ventilator

KDPF

Cooling system

Cooling fan motor

Power train

Power train system

Layout of power train parts

Damper

HST pump

HST motor1

HST motor2

Transfer

Clutch solenoid valve

Drive shaft

Axle

Differential

Torque proportional differential

Limited slip differential

Final drive

Steering system

Layout of steering devices

Steering column

Priority valve

Cushion valve

Emergency steering valve

Orbitrol valve

Brake system

Layout of brake parts

Brake accumulator charge valve

Brake valve

Brake accumulator

Slack adjuster

Brake

Parking brake control

Parking brake

Parking brake solenoid valve

Undercarriage and frame

Axle mount

Center hinge pin

Tire

Hydraulic system

Hydraulic component layout

Work equipment control

Hydraulic tank

Double type gear pump

Steering and work equipment pump

Control valve

CLSS

Hydraulic circuit diagram and names of valves

Self-pressure reducing valve

Work equipment PPC valve

Work equipment lock solenoid valve

PPC circuit accumulator

ECSS accumulator

Work equipment

Work equipment linkage

Bucket

Cab and its attachments

ROPS cab

Cab mount

Electrical system

Engine control system

Preheating system

Engine output limit function

Automatic warm-up function

Parking brake control system

System operating lamp function

Battery disconnect switch function

HST controller system

Machine monitor system

Rearview monitor system

KOMTRAX system

System component parts

Sensor

20 Standard value tables.

Table of contents

Standard service value table

Standard value table for engine

Standard value table for machine

Standard value table for electrical system

30 Testing and adjusting

Table of contents

General information on testing and adjusting

Tools for testing and adjusting

Sketch of tools for testing and adjusting

Engine and cooling system

Testing engine speed

Testing boost pressure

Testing exhaust gas temperature

Testing exhaust gas color

Testing and adjusting valve clearance

Testing compression pressure

Testing blowby pressure

Testing engine oil pressure

Testing EGR valve and KVGT driving oil pressure

Testing fuel pressure

Testing fuel discharge, return and leakage

Bleeding air from fuel system

Testing fuel circuit for leakage

Handling cylinder cutout mode operation

Handling no-injection cranking operation

Testing of KDPF and muffler stack for looseness and damage

Testing of installed condition of cylinder heads and manifolds

Testing engine piping for damage and looseness

Testing and adjusting air conditioner compressor belt tension

Replacing alternator belt

Power train

Testing oil leakage from axle final drive

Testing drive shaft for looseness, backlash, and damage

Testing accelerator pedal

Testing and adjusting HST oil pressure

Testing transfer clutch control pressure

Steering system

Testing directional lever

Testing steering wheel

Testing work equipment control lever

Testing and adjusting steering circuit oil pressure

Bleeding air from steering cylinder circuit

Brake system

Testing brake pedal

Testing braking performance

Testing and adjusting of accumulator charge pressure

Testing wheel brake oil pressure

Testing lowering of wheel brake pressure

Testing wear of wheel brake disc

Bleeding air from wheel brake circuit

Releasing remaining pressure in brake accumulator circuit

Testing parking brake performance

Testing wear of parking brake disc

Testing parking brake release pressure

Method of releasing parking brake manually

Hydraulic system

Testing fan speed

Testing fan circuit oil pressure

Bleeding air from hydraulic fan circuit

Testing and adjusting work equipment PPC oil pressure

Testing and adjusting work equipment oil pressure

Bleeding air from work equipment circuit

Releasing remaining pressure from work equipment circuit

Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas

Work equipment

Testing and adjusting bucket positioner and bucket proximity switch

Testing and adjusting boom position detection lever

Electrical system

Adjusting replaced, reassembled or added sensor, controller, etcwith machine monitor

Special functions of machine monitor

Angle adjustment of rear view camera

Handling voltage circuit of engine controller

Handling battery disconnect switch

Testing diodes

Pm clinic

Pm Clinic service

Check sheet

40 Troubleshooting.

Table of contents

General information on troubleshooting

Troubleshooting points

Sequence of events in troubleshooting

Checks before troubleshooting

Inspection procedure before troubleshooting

Preparation for troubleshooting of electrical system

Classification and procedures for troubleshooting

Symptom and troubleshooting numbers

Information in troubleshooting table

Procedure for troubleshooting wiring harness of pressure sensor system for open circuit

Connector list and layout

Connector contact identification

T-branch box and T-branch adapter table

Fuse location table

Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement

Precautions when performing troubleshooting of machine monitor

Processing procedure of harness checker for troubleshooting of machine monitor LCD unit

Preparation of dummy temperature sensor (for KDOC and KDPF temperature

sensors)

Preparation of short circuit electrical connector (for failure codes [CA1883] and

[CA3135])

Failure codes table

Troubleshooting by failure code (Display of code)

Troubleshooting of electrical system (E-mode)

Troubleshooting of hydraulic and mechanical system (H-mode)

Information described in troubleshooting table (H-mode)

System chart of hydraulic and mechanical systems

Failure mode and cause table

Troubleshooting of engine (S-mode)

Information described in troubleshooting table (S mode)

50 Disassembly and assembly .

Table of contents

General information on disassembly and assembly

How to read this manual

Coating materials list

Special tools list

Sketches of special tools

Engine and cooling system

Removal and installation of supply pump assembly

Removal and installation of injector assembly

Removal and installation of cylinder head assembly

Removal and installation of engine hood assembly

Removal and installation of radiator core assembly

Removal and installation of aftercooler

Removal and installation of hydraulic oil cooler

Removal and installation of engine assembly

Removal and installation of engine front oil seal

Removal and installation of engine rear oil seal

Removal and installation of cooling fan and fan motor assembly

Removal and installation of KDPF assembly

Disassembly and assembly of KDPF assembly

Removal and installation of KCCV assembly

Removal and installation of air cleaner assembly

Removal and installation of KVGT assembly

Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly

Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly

Removal and installation of alternator belt

Removal and installation of fuel tank assembly

Power train

Removal and installation of transfer assembly

Disassembly and assembly of transfer assembly

Removal and installation of front axle assembly

Removal and installation of rear axle assembly

Disassembly and assembly of axle housing assembly

Disassembly and assembly of differential assembly

Undercarriage and frame

Removal and installation of center hinge pin

Removal and installation of counterweight assembly

Hydraulic system

Removal and installation of hydraulic tank assembly

Removal and installation of control valve assembly

Disassembly and assembly of control valve assembly

Removal and installation of hydraulic pump assembly

Removal and installation of HST motor1 assembly

Removal and installation of HST motor2 assembly

Disassembly and assembly of hydraulic cylinder assembly

Work equipment

Removal and installation of work equipment assembly

Cab and its attachments

Removal and installation of operator’s cab and floor frame assembly

Removal and installation of operator’s cab glass (adhered glass)

Removal and installation of operator’s seat assembly

Removal and installation of seat belt

Removal and installation of air conditioner unit assembly

Removal and installation of air conditioner compressor

Removal and installation of air conditioner condenser

Electrical system

Removal and installation of machine monitor assembly

Removal and installation of engine controller assembly

Removal and installation of HST controller assembly

Removal and installation of air conditioner controller assembly

Removal and installation of monitor controller assembly

Removal and installation of mass air flow and temperature sensor

Removal and installation of KOMTRAX terminal assembly

60 Maintenance standard.

Table of contents

Engine and cooling system

Engine related parts

Cooling fan motor

Power train

Damper

Transfer

Drive shaft

Axle

Differential

Limited slip differential

Final drive

Steering system

Steering column

Priority valve

Emergency steering valve

Steering cylinder

Brake system

Brake accumulator charge valve

Slack adjuster

Brake

Parking brake

Parking brake solenoid valve

Undercarriage and frame

Axle mount

Center hinge pin

Hydraulic system

Hydraulic tank

Double type gear pump

Steering and work equipment pump

Control valve

Self-pressure reducing valve

Work equipment PPC valve

Work equipment lock solenoid valve

Work equipment

Work equipment linkage

Bucket

Work equipment cylinder

Cab and its attachments

Cab mount

Electrical system

Bucket positioner

Fork positioner

Remote boom positioner

80 Appendix

Table of contents

Air conditioner components

Precautions for refrigerant

Air conditioner component

Configuration and function of refrigeration cycle

Outline of refrigeration cycle

Air conditioner unit

Dual pressure switch

Air conditioner controller

Compressor

Condenser

Receiver drier

Sunlight sensor

Outer temperature sensor (outside air temperature sensor)

Procedure for testing and troubleshooting

Circuit diagram and arrangement of connector pins

System diagram

Parts and connectors layout

Testing with self-diagnosis function

How to open the electrical system abnormality record screen in service mode of the machine

monitor

Testing temperature control system

Testing vent (mode) changeover

Testing FRESH/RECIRC air changeover

Testing evaporator temperature sensor

Testing relays

Troubleshooting chart 1

Troubleshooting chart 2

Information in troubleshooting table

Failure code list related to air conditioner

Failure code [879AKA] A/C Inner Sensor Open Circuit

Failure code [879AKB] A/C Inner Sensor Short Circuit

Failure code [879BKA] A/C Outer Sensor Open Circuit

Failure code [879BKB] A/C Outer Sensor Short Circuit

Failure code [879CKA] Ventilating Sensor Open Circuit

Failure code [879CKB] Ventilating Sensor Short Circuit

Failure code [879DKZ] Sunlight Sensor Open or Short Circuit

Failure code [879EMC] Ventilation Damper Abnormality

Failure code [879FMC] Air Mix Damper Abnormality

A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)

A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)

A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)

A-4 Troubleshooting for FRESH/RECIRC air changeover

Troubleshooting with gauge pressure

Connection of service tool

Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit

Handling of compressor oil

90 Diagrams and drawings

Table of contents

Hydraulic circuit diagram

Symbols in hydraulic circuit diagram

Hydraulic circuit diagram

Electric circuit diagram

Symbols in electric circuit diagram

Electrical circuit diagram of machine body

Electrical circuit diagram of floor

Index.