Komatsu Wheel Loader WA320, WA320PZ Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheel Loader WA320, WA320PZ, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Wheel Loader WA320, WA320PZ workshop service repair manual includes:
* 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
SEN04162-07 - Wheel Loader WA320-6, WA320PZ-6 Shop Manual.pdf
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
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short....787
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault....789
Failure code [DDD7KY] Travel speed control dial signal: Hot short....791
Failure code [DDE5MA] Emergency steering operation switch: Disconnection....793
Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short....795
Failure code [DDK3KB] Directional selector switch: Ground fault....797
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault....799
Failure code [DDK6KY] FNR lever: Hot short....803
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)....805
360 Troubleshooting by failure code (Display of code), Part 6....808
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault....809
Failure code [DF10KB] Travel speed range selector switch: Hot short....813
Failure code [DGH1KX] HST oil temperature sensor: Ground fault....815
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault....816
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short....817
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault....819
Failure code [DHH1KY] HST oil pressure sensor: Hot short....821
Failure code [DHTCL6] HST filter clogging sensor: Functional defect....823
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short....825
Failure code [DLT3KX] Travel speed sensor B: Abnormality....827
Failure code [DLT4KX] Travel speed sensor A: Abnormality....831
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality....833
Failure code [DV00KY] Alarm buzzer: Hot short....835
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault....837
Failure code [DW26KY] Motor 2 solenoid: Hot short....839
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short....841
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault....843
370 Troubleshooting by failure code (Display of code), Part 7....846
Failure code [DX16KA] Fan EPC solenoid: Disconnection....847
Failure code [DX16KB] Fan EPC solenoid: Ground fault....848
Failure code [DX16KY] Fan EPC solenoid: Hot short....849
Failure code [DX19KA] Motor 1 solenoid: Disconnection....851
Failure code [DX19KB] Motor 1 solenoid: Ground fault....853
Failure code [DX19KY] Motor 1 solenoid: Hot short....855
Failure code [DX20KA] Clutch EPC solenoid: Disconnection....857
Failure code [DX20KB] Clutch EPC solenoid: Ground fault....859
Failure code [DX20KY] Clutch EPC solenoid: Hot short....861
Failure code [DXH7KB] Reverse solenoid: Ground fault....863
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short....865
Failure code [DXH8KB] Forward solenoid: Ground fault....867
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short....869
Failure code [J141N1] Steering pump: Overrun alarm....871
Failure code [M100N1] HST pump: Overrun alarm....871
Failure code [M400N1] Motor 1: Overrun alarm....872
400 Troubleshooting of electrical system (E-mode)....874
E-1 Engine does not start....877
E-2 Preheater does not operate normally....885
E-3 Travel speed is low or high....889
E-4 ECSS does not operate....895
E-5 ECSS keeps operating....898
E-6 Defective boom kick-out function and cancellation....901
E-7 Defective bucket positioner function and cancellation....905
E-8 Defective lift arm FLOATING holding function and cancellation....909
E-9 Travel direction selection system does not function....913
E-10 Fan does not reverse....917
E-11 Fan keeps rotating in reverse....921
E-12 Wiper does not operate....923
E-13 Windshield washer does not operate....927
E-14 Headlamp, clearance lamp and tail lamp do not light up or go off....931
E-15 Working lamp does not light up or go off....939
E-16 Turn signal lamp and hazard lamp do not light up or go off....945
E-17 Brake lamp does not light or it keeps lighting up....951
E-18 Backup lamp does not light or it keeps lighting up....953
E-19 Backup alarm does not sound or it keeps sounding....956
E-20 Horn does not sound or it keeps sounding....959
E-21 Alarm buzzer does not sound or it keeps sounding....961
E-22 Air conditioner does not operate or stop....963
E-23 The KOMTRAX system does not work properly....967
500 Troubleshooting of hydraulic and mechanical system (H-mode)....970
Method of using troubleshooting chart....972
Failure code and cause table....975
H-1 The machine does not start....977
H-2 The travel speed is slow....978
H-3 The traction force is weak....979
H-4 Engine stalls when traveling or engine speed drops excessively....980
H-5 Shift range is not shifted....981
H-6 The steering wheel does not turn....982
H-7 The steering wheel is heavy....983
H-8 Steering wheel shakes or jerks....984
H-9 Machine deviates naturally to one side when traveling....984
H-10 The brake does not work or does not work well....985
H-11 The brake is not released or is dragged....986
H-12 The lift arm does not rise or lower....987
H-13 The lift arm moves slowly or the lift arm rising force is insufficient....988
H-14 When rising, the lift arm comes to move slowly at specific height....989
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)....989
H-16 Hydraulic drifts of the lift arm occur often....989
H-17 The lift arm wobbles during operation....989
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily....990
H-19 The bucket does not tilt back....991
H-20 The bucket moves slowly or the tilting-back force is insufficient....992
H-21 The bucket comes to operate slowly in the midst of tilting-back....993
H-22 The bucket cylinder cannot hold down the bucket....993
H-23 Hydraulic drifts of the bucket occur often....993
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)....993
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily....994
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy....994
H-27 The ECSS does not operate and machine pitches and bounces....995
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)....996
600 Troubleshooting of engine (S-mode)....998
Method of using troubleshooting charts....999
S-1 Starting performance is poor....1003
S-2 Engine does not start....1005
S-3 Engine does not pick up smoothly....1008
S-4 Engine stops during operations....1009
S-5 Engine does not rotate smoothly....1010
S-6 Engine lacks output (or lacks power)....1011
S-7 Exhaust smoke is black (incomplete combustion)....1012
S-8 Oil consumption is excessive (or exhaust smoke is blue)....1013
S-9 Oil becomes contaminated quickly....1014
S-10 Fuel consumption is excessive....1015
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....1016
S-12 Oil pressure drops....1017
S-13 Oil level rises (Entry of coolant or fuel)....1018
S-14 Coolant temperature becomes too high (overheating)....1019
S-15 Abnormal noise is made....1020
S-16 Vibration is excessive....1021
50 Disassembly and assembly....0
100 General information on disassembly and assembly....1024
How to read this manual....1025
Coating materials list....1027
Special tool list....1030
Sketches of special tools....1034
200 Engine and cooling system....1042
Removal and installation of fuel supply pump assembly....1043
Removal and installation of fuel injector assembly....1045
Removal and installation of cylinder head assembly....1053
Removal and installation of engine hood assembly....1065
Removal and installation of radiator....1068
Removal and installation of air aftercooler....1071
Removal and installation of hydraulic oil cooler assembly....1073
Removal and installation of engine assembly....1075
Removal and installation of engine front oil seal assembly....1081
Removal and installation of engine rear oil seal assembly....1084
Removal and installation of cooling fan and fan motor assembly....1087
Removal and installation of fuel tank assembly....1090
310 Power train, Part 1....1094
Removal and installation of transfer....1095
Disassembly and assembly of transfer assembly....1098
Removal and installation of parking brake assembly....1117
Disassembly and assembly of parking brake assembly....1118
320 Power train, Part 2....1124
Removal and installation of front axle assembly....1125
Removal and installation of rear axle assembly....1127
Disassembly and assembly of axle housing assembly....1130
Disassembly and assembly of differential assembly....1142
400 Undercarriage and frame....1166
Removal and installation of center hinge pin....1167
Removal and installation of counterweight....1177
500 Hydraulic system....1180
Removal and installation of HST pump and 4-gear pump assembly....1181
Disassembly and assembly of HST pump assembly....1184
Removal and installation of HST motor 1 assembly....1211
Removal and installation of HST motor 2 assembly....1213
Disassembly and assembly of HST motor assembly....1215
Removal and installation of work equipment control valve assembly....1231
Removal and installation of hydraulic tank assembly....1233
Disassembly and assembly of hydraulic cylinder assembly....1235
600 Work equipment....1244
Removal and installation of work equipment assembly....1245
700 Cab and its attachments....1252
Removal and installation of operator's cab and floor frame assembly....1253
Removal and installation of operator's cab glass (Stuck glass)....1259
Disassembly and assembly of operator's seat assembly....1267
Removal and installation of air conditioner unit....1277
800 Electrical system....1282
Removal and installation of monitor panel....1283
Removal and installation of engine controller assembly....1285
Removal and installation of HST controller assembly....1286
Removal and installation of KOMTRAX terminal assembly....1287
90 Diagrams and drawings....0
100 Hydraulic diagrams and drawings....1290
Automatic greasing circuit diagram....1291
Hydraulic circuit diagram....1294
200 Electrical diagrams and drawings....1298
Common electrical circuit diagram....1300
Connector list and stereogram....1313
SEN03911-04 - Wheel Loader WA320-6, WA320PZ-6 Shop Manual....1316
Cover....1316
00 Index and foreword....0
100 Index....1318
Composition of shop manual....1319
Table of contents....1321
200 Foreword and general information....1332
Safety notice....1333
How to read the shop manual....1338
Explanation of terms for maintenance standard....1340
Handling of electric equipment and hydraulic component....1342
Handling of connectors newly used for engines....1351
How to read electric wire code....1354
Precautions when carrying out operation....1357
Method of disassembling and connecting push-pull type coupler....1360
Standard tightening torque table....1363
Conversion table....1367
01 Specification....0
100 Specification and technical data....1374
Specification dimension drawing....1376
Specifications....1377
Weight table....1381
Table of fuel, coolant and lubricants....1383
10 Structure, function and maintenance standard....0
100 Engine and cooling system....1386
Engine mount and transfer mount....1387
Damper....1388
Cooling system....1389
Cooling system hydraulic piping diagram....1390
Cooling fan motor....1392
200 Power train....1402
Power train....1404
Power train system diagram....1405
Drive shaft....1407
HST hydraulic piping diagram....1408
HST pump....1409
HST motor....1417
Transfer....1423
Clutch solenoid valve....1434
Axle....1435
Differential....1437
Torque proportioning differential....1442
Limited slip differential....1445
Final drive....1449
300 Steering system....1454
Steering piping diagram....1456
Steering column....1457
Priority valve....1458
Orbit-roll valve....1461
Cushion valve....1469
Steering cylinder....1470
Emergency steering piping diagram....1472
Emergency steering valve....1473
Steering relief valve....1476
400 Brake system....1478
Brake piping diagram....1480
Charge valve....1481
Brake valve....1485
Inching valve....1489
Accumulator (for brake)....1490
Slack adjuster....1491
Brake....1493
Parking brake control....1498
Parking brake....1499
500 Undercarriage and frame....1502
Axle mount and center hinge pin....1503
Tires....1508
600 Hydraulic system....1510
Work equipment hydraulic piping diagram....1511
Work equipment control lever linkage....1515
Hydraulic tank....1519
4-gear pump....1521
Work equipment control valve....1523
Cut-off valve....1549
PPC valve....1552
Lock valve....1567
Accumulator (for PPC circuit)....1568
ECSS valve....1570
Accumulator (for ECSS)....1572
700 Work equipment....1574
Work equipment linkage....1575
Bucket....1579
Bucket positioner and boom kick-out....1583
Work equipment cylinder....1595
800 Cab and its attachments....1598
Cab....1600
Air conditioner....1601
910 Electrical system, Part 1....1614
Machine monitor system....1615
Machine monitor....1619
920 Electrical system, Part 2....1642
Electrical system (HST controller system)....1643
HST controller....1659
ECSS system....1661
KOMTRAX system....1663
Engine starting circuit....1665
Engine stopping circuit....1667
Preheating circuit....1668
Engine output derating function....1669
Automatic warm-up function....1669
Parking brake circuit....1671
Coupler plunger control system....1673
Multi-function knob....1674
Max. traction switch....1675
Sensor....1676
20 Standard value table....0
100 Standard service value table....1684
Standard service value table for engine....1685
Standard service value table for chassis....1686
30 Testing and adjusting....0
110 Testing and adjusting, Part 1....1694
Tools for testing, adjusting, and troubleshooting....1696
Measuring engine speed....1701
Measuring exhaust gas color....1703
Adjusting valve clearance....1705
Measuring compression pressure....1707
Measuring blow-by pressure....1710
Measuring engine oil pressure....1711
Measuring intake air (boost) pressure....1712
Handling fuel system equipment....1714
Releasing residual pressure in fuel system....1714
Measuring fuel pressure....1715
Measuring fuel return rate and leakage....1717
Bleeding air from fuel circuit....1721
Checking leakage in fuel system....1722
Handling cylinder cut-out mode operation....1723
Handling no-injection cranking operation....1723
Handling controller voltage circuit....1724
Check of muffler and muffler stack for looseness and damage....1724
Check of muffler function....1725
Check of installed condition of cylinder head and manifolds....1725
Check of engine piping for damage and looseness....1726
Testing and adjusting air conditioner compressor belt tension....1726
Replacing alternator belt....1727
120 Testing and adjusting, Part 2....1730
Checking operating force of accelerator pedal....1732
Checking directional lever....1733
Testing and adjusting HST oil pressure....1734
Testing clutch control pressure....1738
Testing and adjusting steering wheel....1739
Testing and adjusting steering oil pressure....1741
Bleeding air from steering circuit....1743
Testing hydraulic fan....1744
Measuring brake pedal....1746
Testing and adjusting brake pedal linkage....1747
Measuring brake performance....1748
Testing and adjusting accumulator charge pressure....1749
Testing wheel brake oil pressure....1751
Testing wear of brake disc....1754
Bleeding air from wheel brake circuit....1755
Releasing residual pressure in brake accumulator circuit....1756
Testing parking brake performance....1757
Testing and adjusting parking brake control cable....1758
Measuring and adjusting work equipment control lever....1759
Testing and adjusting worke quipment hydraulic pressure....1760
Testing work equipment PPC oil pressure....1761
Bleeding air from hydraulic circuit....1763
Releasing remaining pressure in hydraulic circuit....1764
Testing and adjusting bucket positioner....1765
Testing and adjusting of boom kick-out switch....1766
Checking proximity switch operation pilot lamp....1767
Procedure for testing diodes....1768
Preparation work for troubleshooting for electric system....1769
Starting KOMTRAX terminal operations....1773
Indicator lamps of KOMTRAX terminal....1777
130 Testing and adjusting, Part 3....1782
Adjusting machine monitor....1783
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor....1784
Special functions of machine monitor (EMMS)....1786
Pm clinic inspection chart....1841
40 Troubleshooting....0
100 Failure code table and fuse locations....1844
Failure codes table....1845
Fuse locations....1851
200 General information on troubleshooting....1856
Points to remember when troubleshooting....1857
Sequence of events in troubleshooting....1858
Testing before troubleshooting....1859
Classification and procedures of troubleshooting....1860
Information contained in troubleshooting table....1863
Connection table for connector pin numbers....1865
T- branch box and T- branch adapter table....1901
310 Troubleshooting by failure code (Display of code), Part 1....1906
Failure code [2G40ZG] Brake: Oil pressure reduction....1907
Failure code [6091NX] HST filter: Clogging....1909
Failure code [989FN1] Travel speed: Overrun alarm....1911
Failure code [AA1ANX] Air cleaner: Clogging....1913
Failure code [AB00L6] Alternator R system: Hot short....1915
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage....1917
Failure code [B@BAZG] Engine: Oil pressure reduction....1919
Failure code [B@BAZK] Engine oil: Low level....1920
Failure code [B@BCNS] Engine: Overheat....1921
Failure code [B@BCZK] Engine: Low coolant level....1923
Failure code [B@C6NS] Front brake: High oil temperature....1925
Failure code [B@CRNS] HST: High oil temperature....1926
320 Troubleshooting by failure code (Display of code), Part 2....1928
Failure code [CA111] Abnormality in engine controller....1930
Failure code [CA115] Engine Ne or Bkup speed sensor error....1931
Failure code [CA122] Charge pressure sensor high error....1933
Failure code [CA123] Charge pressure sensor low error....1935
Failure code [CA131] Throttle sensor high error....1937
Failure code [CA132] Throttle sensor low error....1939
Failure code [CA144] Coolant sensor high error....1941
Failure code [CA145] Coolant sensor low error....1943
Failure code [CA153] Charge temperature sensor high error....1945
Failure code [CA154] Charge temperature sensor low error....1947
Failure code [CA155] Derating of speed by abnormally high charge temperature....1949
Failure code [CA187] Sensor power supply 2 low error....1951
Failure code [CA221] Atmospheric pressure sensor high error....1953
Failure code [CA222] Atmospheric sensor low error....1955
Failure code [CA227] Sensor power supply 2 high error....1957
Failure code [CA234] Engine overspeed....1958
Failure code [CA238] Ne speed sensor power supply error....1959
Failure code [CA271] IMV (IMA) Short circuit....1960
Failure code [CA272] IMV (IMA) Disconnection....1961
Failure code [CA322] Injector #1 open/short error....1963
Failure code [CA323] Injector #5 open/short error....1965
Failure code [CA324] Injector #3 open/short error....1967
Failure code [CA325] Injector #6 open/short error....1969
Failure code [CA331] Injector #2 open/short error....1971
Failure code [CA332] Injector #4 open/short error....1973
Failure code [CA342] Calibration code inconsistency....1975
Failure code [CA351] Injectors drive circuit error....1977
Failure code [CA352] Sensor power supply 1 low error....1979
Failure code [CA386] Sensor power supply 1 high error....1981
330 Troubleshooting by failure code (Display of code), Part 3....1984
Failure code [CA428] Abnormally high level in water sensor....1987
Failure code [CA429] Abnormally low level in water sensor....1989
Failure code [CA431] Idle validation switch error....1991
Failure code [CA432] Idle validation action error....1995
Failure code [CA435] Engine oil pressure switch error....1999
Failure code [CA441] Battery voltage low error....2000
Failure code [CA442] Battery voltage high error....2003
Failure code [CA449] Common rail pressure high error 2....2005
Failure code [CA451] Common rail pressure sensor high error....2007
Failure code [CA452] Common rail pressure sensor low error....2009
Failure code [CA488] Derating of torque by abnormally high charge temperature....2011
Failure code [CA553] Common rail pressure high error 1....2012
Failure code [CA559] Supply pump pressure very low error....2013
Failure code [CA689] Engine Ne speed sensor error....2015
Failure code [CA731] Engine Bkup speed sensor phase error....2017
Failure code [CA757] All continuous data lost error....2018
Failure code [CA778] Engine Bkup speed sensor error....2021
Failure code [CA1633] KOMNET datalink timeout error....2023
Failure code [CA2185] Throttle sensor supply voltage high error....2027
Failure code [CA2186] Throttle sensor power supply low error....2029
Failure code [CA2249] Supply pump pressure very low error 2....2031
Failure code [CA2311] Abnormality in IMV (IMA) solenoid....2033
Failure code [CA2555] Intake heater relay disconnection error....2035
Failure code [CA2556] Intake heater relay short circuit error....2037
340 Troubleshooting by failure code (Display of code), Part 4....2040
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short....2041
Failure code [D192KY] ECSS solenoid relay: Hot short....2043
Failure code [D1B0KA] HST safety relay: Disconnection....2045
Failure code [D1B0KB] HST safety relay: Ground fault....2047
Failure code [D1B0KY] HST safety relay: Hot short....2049
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection....2051
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection....2053
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection....2055
Failure code [DAJ0KK] HST controller power supply: Low voltage....2059
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality....2061
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault....2063
Failure code [DAJ1L6] HST controller main power line: Hot short....2065
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage....2067
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness....2069
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault....2071
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range....2073
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals....2075
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection....2076
Failure code [DAJRMA] HST controller: Disagreement in option selection....2082
350 Troubleshooting by failure code (Display of code), Part 5....2084
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line....2085
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality....2091
Failure code [DD1NLD] Fan reverse switch signal: Abnormality....2093
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short....2095
Failure code [DDB6KB] Parking brake indicator signal: Ground fault....2097
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble....2099
Failure code [DDB6L0] Parking brake reminder signal: Ground fault....2101
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short....2103
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault....2105
Failure code [DDD7KY] Travel speed control dial signal: Hot short....2107
Failure code [DDE5MA] Emergency steering operation switch: Disconnection....2109
Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short....2111
Failure code [DDK3KB] Directional selector switch: Ground fault....2113
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault....2115
Failure code [DDK6KY] FNR lever: Hot short....2119
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)....2121
360 Troubleshooting by failure code (Display of code), Part 6....2124
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault....2125
Failure code [DF10KB] Travel speed range selector switch: Hot short....2129
Failure code [DGH1KX] HST oil temperature sensor: Ground fault....2131
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault....2132
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short....2133
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault....2135
Failure code [DHH1KY] HST oil pressure sensor: Hot short....2137
Failure code [DHTCL6] HST filter clogging sensor: Functional defect....2139
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short....2141
Failure code [DLT3KX] Travel speed sensor B: Abnormality....2143
Failure code [DLT4KX] Travel speed sensor A: Abnormality....2147
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality....2149
Failure code [DV00KY] Alarm buzzer: Hot short....2151
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault....2153
Failure code [DW26KY] Motor 2 solenoid: Hot short....2155
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short....2157
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault....2159
370 Troubleshooting by failure code (Display of code), Part 7....2162
Failure code [DX16KA] Fan EPC solenoid: Disconnection....2163
Failure code [DX16KB] Fan EPC solenoid: Ground fault....2164
Failure code [DX16KY] Fan EPC solenoid: Hot short....2165
Failure code [DX19KA] Motor 1 solenoid: Disconnection....2167
Failure code [DX19KB] Motor 1 solenoid: Ground fault....2169
Failure code [DX19KY] Motor 1 solenoid: Hot short....2171
Failure code [DX20KA] Clutch EPC solenoid: Disconnection....2173
Failure code [DX20KB] Clutch EPC solenoid: Ground fault....2175
Failure code [DX20KY] Clutch EPC solenoid: Hot short....2177
Failure code [DXH7KB] Reverse solenoid: Ground fault....2179
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short....2181
Failure code [DXH8KB] Forward solenoid: Ground fault....2183
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short....2185
Failure code [J141N1] Steering pump: Overrun alarm....2187
Failure code [M100N1] HST pump: Overrun alarm....2187
Failure code [M400N1] Motor 1: Overrun alarm....2188
400 Troubleshooting of electrical system (E-mode)....2190
E-1 Engine does not start....2193
E-2 Preheater does not operate normally....2201
E-3 Travel speed is low or high....2205
E-4 ECSS does not operate....2211
E-5 ECSS keeps operating....2214
E-6 Defective boom kick-out function and cancellation....2217
E-7 Defective bucket positioner function and cancellation....2221
E-8 Defective lift arm FLOATING holding function and cancellation....2225
E-9 Travel direction selection system does not function....2229
E-10 Fan does not reverse....2233
E-11 Fan keeps rotating in reverse....2237
E-12 Wiper does not operate....2239
E-13 Windshield washer does not operate....2243
E-14 Headlamp, clearance lamp and tail lamp do not light up or go off....2247
E-15 Working lamp does not light up or go off....2255
E-16 Turn signal lamp and hazard lamp do not light up or go off....2261
E-17 Brake lamp does not light or it keeps lighting up....2267
E-18 Backup lamp does not light or it keeps lighting up....2269
E-19 Backup alarm does not sound or it keeps sounding....2272
E-20 Horn does not sound or it keeps sounding....2275
E-21 Alarm buzzer does not sound or it keeps sounding....2277
E-22 Air conditioner does not operate or stop....2279
E-23 The KOMTRAX system does not work properly....2283
500 Troubleshooting of hydraulic and mechanical system (H-mode)....2286
Method of using troubleshooting chart....2288
Failure code and cause table....2291
H-1 The machine does not start....2293
H-2 The travel speed is slow....2294
H-3 The traction force is weak....2295
H-4 Engine stalls when traveling or engine speed drops excessively....2296
H-5 Shift range is not shifted....2297
H-6 The steering wheel does not turn....2298
H-7 The steering wheel is heavy....2299
H-8 Steering wheel shakes or jerks....2300
H-9 Machine deviates naturally to one side when traveling....2300
H-10 The brake does not work or does not work well....2301
H-11 The brake is not released or is dragged....2302
H-12 The lift arm does not rise or lower....2303
H-13 The lift arm moves slowly or the lift arm rising force is insufficient....2304
H-14 When rising, the lift arm comes to move slowly at specific height....2305
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)....2305
H-16 Hydraulic drifts of the lift arm occur often....2305
H-17 The lift arm wobbles during operation....2305
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily....2306
H-19 The bucket does not tilt back....2307
H-20 The bucket moves slowly or the tilting-back force is insufficient....2308
H-21 The bucket comes to operate slowly in the midst of tilting-back....2309
H-22 The bucket cylinder cannot hold down the bucket....2309
H-23 Hydraulic drifts of the bucket occur often....2309
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)....2309
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily....2310
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy....2310
H-27 The ECSS does not operate and machine pitches and bounces....2311
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)....2312
600 Troubleshooting of engine (S-mode)....2314
Method of using troubleshooting charts....2315
S-1 Starting performance is poor....2319
S-2 Engine does not start....2321
S-3 Engine does not pick up smoothly....2324
S-4 Engine stops during operations....2325
S-5 Engine does not rotate smoothly....2326
S-6 Engine lacks output (or lacks power)....2327
S-7 Exhaust smoke is black (incomplete combustion)....2328
S-8 Oil consumption is excessive (or exhaust smoke is blue)....2329
S-9 Oil becomes contaminated quickly....2330
S-10 Fuel consumption is excessive....2331
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....2332
S-12 Oil pressure drops....2333
S-13 Oil level rises (Entry of coolant or fuel)....2334
S-14 Coolant temperature becomes too high (overheating)....2335
S-15 Abnormal noise is made....2336
S-16 Vibration is excessive....2337
50 Disassembly and assembly....0
100 General information on disassembly and assembly....2340
How to read this manual....2341
Coating materials list....2343
Special tool list....2346
Sketches of special tools....2350
200 Engine and cooling system....2358
Removal and installation of fuel supply pump assembly....2359
Removal and installation of fuel injector assembly....2361
Removal and installation of cylinder head assembly....2369
Removal and installation of engine hood assembly....2381
Removal and installation of radiator....2384
Removal and installation of air aftercooler....2387
Removal and installation of hydraulic oil cooler assembly....2389
Removal and installation of engine assembly....2391
Removal and installation of engine front oil seal assembly....2397
Removal and installation of engine rear oil seal assembly....2400
Removal and installation of cooling fan and fan motor assembly....2403
Removal and installation of fuel tank assembly....2406
310 Power train, Part 1....2410
Removal and installation of transfer....2411
Disassembly and assembly of transfer assembly....2414
Removal and installation of parking brake assembly....2433
Disassembly and assembly of parking brake assembly....2434
320 Power train, Part 2....2440
Removal and installation of front axle assembly....2441
Removal and installation of rear axle assembly....2443
Disassembly and assembly of axle housing assembly....2446
Disassembly and assembly of differential assembly....2458
400 Undercarriage and frame....2482
Removal and installation of center hinge pin....2483
Removal and installation of counterweight....2493
500 Hydraulic system....2496
Removal and installation of HST pump and 4-gear pump assembly....2497
Disassembly and assembly of HST pump assembly....2500
Removal and installation of HST motor 1 assembly....2527
Removal and installation of HST motor 2 assembly....2529
Disassembly and assembly of HST motor assembly....2531
Removal and installation of work equipment control valve assembly....2547
Removal and installation of hydraulic tank assembly....2549
Disassembly and assembly of hydraulic cylinder assembly....2551
600 Work equipment....2560
Removal and installation of work equipment assembly....2561
700 Cab and its attachments....2568
Removal and installation of operator's cab and floor frame assembly....2569
Removal and installation of operator's cab glass (Stuck glass)....2575
Disassembly and assembly of operator's seat assembly....2583
Removal and installation of air conditioner unit....2593
800 Electrical system....2598
Removal and installation of monitor panel....2599
Removal and installation of engine controller assembly....2601
Removal and installation of HST controller assembly....2602
Removal and installation of KOMTRAX terminal assembly....2603
90 Diagrams and drawings....0
100 Hydraulic diagrams and drawings....2606
Automatic greasing circuit diagram....2607
Hydraulic circuit diagram....2610
200 Electrical diagrams and drawings....2614
Common electrical circuit diagram....2616
Connector list and stereogram....2629
SEN04162-07 - Wheel Loader WA320-6, WA320PZ-6 Shop Manual....2632
COVER....2632
00 Index and foreword....0
100 Index....2634
Composition of shop manual....2635
Table of contents....2637
200 Foreword and general information....2648
Safety notice....2649
How to read the shop manual....2654
Explanation of terms for maintenance standard....2656
Handling of electric equipment and hydraulic component....2658
Handling of connectors newly used for engines....2667
How to read electric wire code....2670
Precautions when carrying out operation....2673
Method of disassembling and connecting push-pull type coupler....2676
Standard tightening torque table....2679
Conversion table....2683
01 Specification....0
100 Specification and technical data....2690
Specification dimension drawing....2692
Specifications....2693
Weight table....2697
Table of fuel, coolant and lubricants....2699
10 Structure, function and maintenance standard....0
100 Engine and cooling system....2702
Engine mount and transfer mount....2703
Damper....2704
Cooling system....2705
Cooling system hydraulic piping diagram....2706
Cooling fan motor....2708
200 Power train....2718
Power train....2720
Power train system diagram....2721
Drive shaft....2723
HST hydraulic piping diagram....2724
HST pump....2725
HST motor....2733
Transfer....2739
Clutch solenoid valve....2750
Axle....2751
Differential....2753
Torque proportioning differential....2758
Limited slip differential....2761
Final drive....2765
300 Steering system....2770
Steering piping diagram....2772
Steering column....2773
Priority valve....2774
Orbit-roll valve....2777
Cushion valve....2785
Steering cylinder....2786
Emergency steering piping diagram....2788
Emergency steering valve....2789
Steering relief valve....2792
400 Brake system....2794
Brake piping diagram....2796
Charge valve....2797
Brake valve....2801
Inching valve....2805
Accumulator (for brake)....2806
Slack adjuster....2807
Brake....2809
Parking brake control....2814
Parking brake....2815
500 Undercarriage and frame....2818
Axle mount and center hinge pin....2819
Tires....2824
600 Hydraulic system....2826
Work equipment hydraulic piping diagram....2827
Work equipment control lever linkage....2831
Hydraulic tank....2835
4-gear pump....2837
Work equipment control valve....2839
Cut-off valve....2865
PPC valve....2868
Lock valve....2883
Accumulator (for PPC circuit)....2884
ECSS valve....2886
Accumulator (for ECSS)....2888
700 Work equipment....2890
Work equipment linkage....2891
Bucket....2895
Bucket positioner and boom kick-out....2899
Work equipment cylinder....2911
800 Cab and its attachments....2914
Cab....2916
Air conditioner....2917
910 Electrical system, Part 1....2930
Machine monitor system....2931
Machine monitor....2935
920 Electrical system, Part 2....2958
Electrical system (HST controller system)....2959
HST controller....2975
ECSS system....2977
KOMTRAX system....2979
Engine starting circuit....2981
Engine stopping circuit....2983
Preheating circuit....2984
Engine output derating function....2985
Automatic warm-up function....2985
Parking brake circuit....2987
Coupler plunger control system....2989
Max. traction switch....2990
Multi-function knob....2991
Sensor....2992
20 Standard value table....0
100 Standard service value table....3000
Standard service value table for engine....3001
Standard service value table for chassis....3002
30 Testing and adjusting....0
110 Testing and adjusting, Part 1....3010
Tools for testing, adjusting, and troubleshooting....3012
Measuring engine speed....3017
Measuring exhaust gas color....3019
Adjusting valve clearance....3021
Measuring compression pressure....3023
Measuring blow-by pressure....3026
Measuring engine oil pressure....3027
Measuring intake air (boost) pressure....3028
Handling fuel system equipment....3030
Releasing residual pressure in fuel system....3030
Measuring fuel pressure....3031
Measuring fuel return rate and leakage....3033
Bleeding air from fuel circuit....3037
Checking leakage in fuel system....3038
Handling cylinder cut-out mode operation....3039
Handling no-injection cranking operation....3039
Handling controller voltage circuit....3040
Check of muffler and muffler stack for looseness and damage....3040
Check of muffler function....3041
Check of installed condition of cylinder head and manifolds....3041
Check of engine piping for damage and looseness....3042
Testing and adjusting air conditioner compressor belt tension....3042
Replacing alternator belt....3043
120 Testing and adjusting, Part 2....3046
Checking operating force of accelerator pedal....3048
Checking directional lever....3049
Testing and adjusting HST oil pressure....3050
Testing clutch control pressure....3054
Testing and adjusting steering wheel....3055
Testing and adjusting steering oil pressure....3057
Bleeding air from steering circuit....3059
Testing hydraulic fan....3060
Measuring brake pedal....3062
Testing and adjusting brake pedal linkage....3063
Measuring brake performance....3064
Testing and adjusting accumulator charge pressure....3065
Testing wheel brake oil pressure....3067
Testing wear of brake disc....3070
Bleeding air from wheel brake circuit....3071
Releasing residual pressure in brake accumulator circuit....3072
Testing parking brake performance....3073
Testing and adjusting parking brake control cable....3074
Measuring and adjusting work equipment control lever....3075
Testing and adjusting work equipment hydraulic pressure....3076
Testing work equipment PPC oil pressure....3077
Bleeding air from hydraulic circuit....3079
Releasing remaining pressure in hydraulic circuit....3080
Testing and adjusting bucket positioner....3081
Testing and adjusting of boom kick-out switch....3082
Checking proximity switch operation pilot lamp....3083
Procedure for testing diodes....3084
Preparation work for troubleshooting for electric system....3085
Starting KOMTRAX terminal operations....3089
Indicator lamps of KOMTRAX terminal....3093
130 Testing and adjusting, Part 3....3098
Adjusting machine monitor....3099
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor....3100
Special functions of machine monitor (EMMS)....3102
Pm clinic inspection chart....3155
40 Troubleshooting....0
100 Failure code table and fuse locations....3158
Failure codes table....3159
Fuse locations....3165
200 General information on troubleshooting....3170
Points to remember when troubleshooting....3171
Sequence of events in troubleshooting....3172
Testing before troubleshooting....3173
Classification and procedures of troubleshooting....3174
Information contained in troubleshooting table....3177
Connection table for connector pin numbers....3179
T- branch box and T- branch adapter table....3215
310 Troubleshooting by failure code (Display of code), Part 1....3220
Failure code [2G40ZG] Brake: Oil pressure reduction....3221
Failure code [6091NX] HST filter: Clogging....3223
Failure code [989FN1] Travel speed: Overrun alarm....3224
Failure code [AA1ANX] Air cleaner: Clogging....3225
Failure code [AB00L6] Alternator R system: Hot short....3227
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage....3229
Failure code [B@BAZG] Engine: Oil pressure reduction....3231
Failure code [B@BAZK] Engine oil: Low level....3232
Failure code [B@BCNS] Engine: Overheat....3233
Failure code [B@BCZK] Engine: Low coolant level....3235
Failure code [B@C6NS] Front brake: High oil temperature....3237
Failure code [B@CRNS] HST: High oil temperature....3238
320 Troubleshooting by failure code (Display of code), Part 2....3240
Failure code [CA111] Abnormality in engine controller....3242
Failure code [CA115] Engine Ne or Bkup speed sensor error....3243
Failure code [CA122] Charge pressure sensor high error....3245
Failure code [CA123] Charge pressure sensor low error....3247
Failure code [CA131] Throttle sensor high error....3249
Failure code [CA132] Throttle sensor low error....3251
Failure code [CA144] Coolant sensor high error....3253
Failure code [CA145] Coolant sensor low error....3255
Failure code [CA153] Charge temperature sensor high error....3257
Failure code [CA154] Charge temperature sensor low error....3259
Failure code [CA155] Derating of speed by abnormally high charge temperature....3261
Failure code [CA187] Sensor power supply 2 low error....3263
Failure code [CA221] Atmospheric pressure sensor high error....3265
Failure code [CA222] Atmospheric sensor low error....3267
Failure code [CA227] Sensor power supply 2 high error....3269
Failure code [CA234] Engine overspeed....3270
Failure code [CA238] Ne speed sensor power supply error....3271
Failure code [CA271] IMV (IMA) Short circuit....3272
Failure code [CA272] IMV (IMA) Disconnection....3273
Failure code [CA322] Injector #1 open/short error....3275
Failure code [CA323] Injector #5 open/short error....3277
Failure code [CA324] Injector #3 open/short error....3279
Failure code [CA325] Injector #6 open/short error....3281
Failure code [CA331] Injector #2 open/short error....3283
Failure code [CA332] Injector #4 open/short error....3285
Failure code [CA342] Calibration code inconsistency....3287
Failure code [CA351] Injectors drive circuit error....3289
Failure code [CA352] Sensor power supply 1 low error....3291
Failure code [CA386] Sensor power supply 1 high error....3293
330 Troubleshooting by failure code (Display of code), Part 3....3296
Failure code [CA428] Abnormally high level in water sensor....3299
Failure code [CA429] Abnormally low level in water sensor....3301
Failure code [CA431] Idle validation switch error....3303
Failure code [CA432] Idle validation action error....3307
Failure code [CA435] Engine oil pressure switch error....3311
Failure code [CA441] Battery voltage low error....3312
Failure code [CA442] Battery voltage high error....3315
Failure code [CA449] Common rail pressure high error 2....3317
Failure code [CA451] Common rail pressure sensor high error....3319
Failure code [CA452] Common rail pressure sensor low error....3321
Failure code [CA488] Derating of torque by abnormally high charge temperature....3323
Failure code [CA553] Common rail pressure high error 1....3324
Failure code [CA559] Supply pump pressure very low error....3325
Failure code [CA689] Engine Ne speed sensor error....3327
Failure code [CA731] Engine Bkup speed sensor phase error....3329
Failure code [CA757] All continuous data lost error....3330
Failure code [CA778] Engine Bkup speed sensor error....3333
Failure code [CA1633] KOMNET datalink timeout error....3335
Failure code [CA2185] Throttle sensor supply voltage high error....3339
Failure code [CA2186] Throttle sensor power supply low error....3341
Failure code [CA2249] Supply pump pressure very low error 2....3343
Failure code [CA2311] Abnormality in IMV (IMA) solenoid....3345
Failure code [CA2555] Intake heater relay disconnection error....3347
Failure code [CA2556] Intake heater relay short circuit error....3349
340 Troubleshooting by failure code (Display of code), Part 4....3352
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short....3353
Failure code [D192KY] ECSS solenoid relay: Hot short....3355
Failure code [D1B0KA] HST safety relay: Disconnection....3357
Failure code [D1B0KB] HST safety relay: Ground fault....3359
Failure code [D1B0KY] HST safety relay: Hot short....3361
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection....3363
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection....3365
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection....3367
Failure code [DAJ0KK] HST controller power supply: Low voltage....3371
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality....3373
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault....3375
Failure code [DAJ1L6] HST controller main power line: Hot short....3377
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage....3379
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness....3381
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault....3383
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range....3385
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals....3387
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection....3388
Failure code [DAJRMA] HST controller: Disagreement in option selection....3394
350 Troubleshooting by failure code (Display of code), Part 5....3396
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line....3397
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality....3403
Failure code [DD1NLD] Fan reverse switch signal: Abnormality....3405
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short....3407
Failure code [DDB6KB] Parking brake indicator signal: Ground fault....3409
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble....3411
Failure code [DDB6L0] Parking brake reminder signal: Ground fault....3413
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short....3415
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault....3417
Failure code [DDD7KY] Travel speed control dial signal: Hot short....3419
Failure code [DDE5MA] Emergency steering operation switch: Disconnection....3421
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault....3423
Failure code [DDK6KY] FNR lever: Hot short....3427
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)....3429
360 Troubleshooting by failure code (Display of code), Part 6....3432
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault....3433
Failure code [DF10KB] Travel speed range selector switch: Hot short....3437
Failure code [DGH1KX] HST oil temperature sensor: Ground fault....3439
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault....3440
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short....3441
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault....3443
Failure code [DHH1KY] HST oil pressure sensor: Hot short....3445
Failure code [DHTCL6] HST filter clogging sensor: Functional defect....3447
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short....3449
Failure code [DLT3KX] Travel speed sensor B: Abnormality....3451
Failure code [DLT4KX] Travel speed sensor A: Abnormality....3455
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality....3457
Failure code [DV00KY] Alarm buzzer: Hot short....3459
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault....3461
Failure code [DW26KY] Motor 2 solenoid: Hot short....3463
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short....3465
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault....3467
370 Troubleshooting by failure code (Display of code), Part 7....3470
Failure code [DX16KA] Fan EPC solenoid: Disconnection....3471
Failure code [DX16KB] Fan EPC solenoid: Ground fault....3472
Failure code [DX16KY] Fan EPC solenoid: Hot short....3473
Failure code [DX19KA] Motor 1 solenoid: Disconnection....3475
Failure code [DX19KB] Motor 1 solenoid: Ground fault....3477
Failure code [DX19KY] Motor 1 solenoid: Hot short....3479
Failure code [DX20KA] Clutch EPC solenoid: Disconnection....3481
Failure code [DX20KB] Clutch EPC solenoid: Ground fault....3483
Failure code [DX20KY] Clutch EPC solenoid: Hot short....3485
Failure code [DXH7KB] Reverse solenoid: Ground fault....3487
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short....3489
Failure code [DXH8KB] Forward solenoid: Ground fault....3491
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short....3493
Failure code [J141N1] Steering pump: Overrun alarm....3495
Failure code [M100N1] HST pump: Overrun alarm....3495
Failure code [M400N1] Motor 1: Overrun alarm....3496
400 Troubleshooting of electrical system (E-mode)....3498
E-1 Engine does not start....3500
E-2 Preheater does not operate normally....3507
E-3 Travel speed is low or high....3511
E-4 ECSS does not operate....3517
E-5 ECSS keeps operating....3520
E-6 Defective boom kick-out function and cancellation....3523
E-7 Defective bucket positioner function and cancellation....3527
E-8 Defective lift arm FLOATING holding function and cancellation....3531
E-9 Travel direction selection system does not function....3535
E-10 Fan does not reverse....3539
E-11 Fan keeps rotating in reverse....3543
E-12 Wiper does not operate....3545
E-13 Windshield washer does not operate....3549
E-14 Headlamp, clearance lamp and tail lamp do not light up or go off....3553
E-15 Working lamp does not light up or go off....3561
E-16 Turn signal lamp and hazard lamp do not light up or go off....3567
E-17 Brake lamp does not light or it keeps lighting up....3573
E-18 Backup lamp does not light or it keeps lighting up....3575
E-19 Backup alarm does not sound or it keeps sounding....3578
E-20 Horn does not sound or it keeps sounding....3581
E-21 Alarm buzzer does not sound or it keeps sounding....3583
E-22 Air conditioner does not operate or stop....3585
E-23 The KOMTRAX system does not work properly....3589
500 Troubleshooting of hydraulic and mechanical system (H-mode)....3592
Method of using troubleshooting chart....3594
Failure code and cause table....3597
H-1 The machine does not start....3599
H-2 The travel speed is slow....3600
H-3 The traction force is weak....3601
H-4 Engine stalls when traveling or engine speed drops excessively....3602
H-5 Shift range is not shifted....3603
H-6 The steering wheel does not turn....3604
H-7 The steering wheel is heavy....3605
H-8 Steering wheel shakes or jerks....3606
H-9 Machine deviates naturally to one side when traveling....3606
H-10 The brake does not work or does not work well....3607
H-11 The brake is not released or is dragged....3608
H-12 The lift arm does not rise or lower....3609
H-13 The lift arm moves slowly or the lift arm rising force is insufficient....3610
H-14 When rising, the lift arm comes to move slowly at specific height....3611
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)....3611
H-16 Hydraulic drifts of the lift arm occur often....3611
H-17 The lift arm wobbles during operation....3611
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily....3612
H-19 The bucket does not tilt back....3613
H-20 The bucket moves slowly or the tilting-back force is insufficient....3614
H-21 The bucket comes to operate slowly in the midst of tilting-back....3615
H-22 The bucket cylinder cannot hold down the bucket....3615
H-23 Hydraulic drifts of the bucket occur often....3615
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)....3615
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily....3616
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy....3616
H-27 The ECSS does not operate and machine pitches and bounces....3617
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)....3618
600 Troubleshooting of engine (S-mode)....3620
Method of using troubleshooting charts....3621
S-1 Starting performance is poor....3625
S-2 Engine does not start....3627
S-3 Engine does not pick up smoothly....3630
S-4 Engine stops during operations....3631
S-5 Engine does not rotate smoothly....3632
S-6 Engine lacks output (or lacks power)....3633
S-7 Exhaust smoke is black (incomplete combustion)....3634
S-8 Oil consumption is excessive (or exhaust smoke is blue)....3635
S-9 Oil becomes contaminated quickly....3636
S-10 Fuel consumption is excessive....3637
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....3638
S-12 Oil pressure drops....3639
S-13 Oil level rises (Entry of coolant or fuel)....3640
S-14 Coolant temperature becomes too high (overheating)....3641
S-15 Abnormal noise is made....3642
S-16 Vibration is excessive....3643
50 Disassembly and assembly....0
100 General information on disassembly and assembly....3646
How to read this manual....3647
Coating materials list....3649
Special tool list....3652
Sketches of special tools....3656
200 Engine and cooling system....3664
Removal and installation of fuel supply pump assembly....3665
Removal and installation of fuel injector assembly....3668
Removal and installation of cylinder head assembly....3676
Removal and installation of engine hood assembly....3688
Removal and installation of radiator....3691
Removal and installation of air aftercooler....3694
Removal and installation of hydraulic oil cooler assembly....3696
Removal and installation of engine assembly....3698
Removal and installation of engine front oil seal assembly....3704
Removal and installation of engine rear oil seal assembly....3707
Removal and installation of cooling fan and fan motor assembly....3710
Removal and installation of fuel tank assembly....3713
310 Power train, Part 1....3716
Removal and installation of transfer assembly....3717
Disassembly and assembly of transfer assembly....3720
Removal and installation of parking brake assembly....3739
Disassembly and assembly of parking brake assembly....3740
320 Power train, Part 2....3746
Removal and installation of front axle assembly....3747
Removal and installation of rear axle assembly....3749
Disassembly and assembly of axle housing assembly....3752
Disassembly and assembly of differential assembly....3764
400 Undercarriage and frame....3788
Removal and installation of center hinge pin....3789
Removal and installation of counterweight assembly....3799
500 Hydraulic system....3802
Removal and installation of HST pump and 4-gear pump assembly....3803
Disassembly and assembly of HST pump assembly....3806
Removal and installation of HST motor 1 assembly....3833
Removal and installation of HST motor 2 assembly....3835
Disassembly and assembly of HST motor assembly....3837
Removal and installation of work equipment control valve assembly....3853
Removal and installation of hydraulic tank assembly....3855
Disassembly and assembly of hydraulic cylinder assembly....3857
600 Work equipment....3866
Removal and installation of work equipment assembly....3867
700 Cab and its attachments....3874
Removal and installation of operator's cab and floor frame assembly....3875
Removal and installation of operator's cab glass (Stuck glass)....3881
Disassembly and assembly of operator's seat assembly....3889
Removal and installation of air conditioner unit....3899
800 Electrical system....3904
Removal and installation of monitor panel....3905
Removal and installation of engine controller assembly....3907
Removal and installation of HST controller assembly....3908
Removal and installation of KOMTRAX terminal assembly....3909
90 Diagrams and drawings....0
100 Hydraulic diagrams and drawings....3912
Automatic greasing circuit diagram....3913
Hydraulic circuit diagram....3916
200 Electrical diagrams and drawings....3920
Common electrical circuit diagram....3922
Connector list and stereogram....3935
TEN00265-04 - Wheel Loader WA320PZ-6 Operation & Maintenance Manual....3938
COVER....3938
FOREWORD....3939
BEFORE READING THIS MANUAL....3940
SAFETY INFORMATION....3941
INTRODUCTION....3942
USE OF MACHINE....3942
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....3942
VISIBILITY FROM OPERATOR'S SEAT....3942
NECESSARY INFORMATION....3943
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....3943
EPA REGULATIONS, ENGINE NUMBER PLATE....3943
POSITION OF SERVICE METER....3944
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....3944
CONTENTS....3945
SAFETY....3949
SAFETY....3950
SAFETY LABELS....3953
LOCATION OF SAFETY LABELS....3953
SAFETY LABELS....3954
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....3961
PRECAUTIONS BEFORE STARTING OPERATION....3961
PREPARATIONS FOR SAFE OPERATION....3961
FIRE PREVENTION....3963
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....3964
DO NOT GET CAUGHT IN ARTICULATING PORTION....3967
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....3967
UNAUTHORIZED MODIFICATION....3967
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....3967
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....3968
PRECAUTIONS FOR OPERATION....3969
PRECAUTIONS FOR JOBSITE....3969
STARTING ENGINE....3971
OPERATION....3974
TRANSPORTATION....3980
TOWING....3981
PRECAUTIONS FOR MAINTENANCE....3982
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....3982
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....3987
TIRES....3992
OPERATION....3995
GENERAL VIEW....3996
GENERAL VIEW OF MACHINE....3996
GENERAL VIEW OF CONTROLS AND GAUGES....3997
EXPLANATION OF COMPONENTS....3999
MACHINE MONITOR....3999
SWITCHES....4036
CONTROL LEVERS, PEDALS....4050
STEERING TILT LOCK LEVER....4055
CAP AND COVER WITH LOCK....4055
FRAME LOCK BAR....4056
TOWING PIN....4057
GREASE PUMP....4057
OPENING, CLOSING CAB DOORS, WINDOWS....4058
FUSE....4062
SLOW BLOW FUSE....4064
POWER OUTLET....4065
STORAGE BOX....4065
AM/FM RADIO-CASSETTE STEREO....4066
AIR CONDITIONER....4074
HANDLING CAB WIPER....4081
OPERATION....4082
CHECK BEFORE STARTING ENGINE, ADJUST....4082
STARTING ENGINE....4100
CHECKS AFTER STARTING ENGINE....4104
OPERATIONS AND CHECKS AFTER STARTING ENGINE....4105
STOPPING ENGINE....4108
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....4109
TURNING....4115
OPERATION OF WORK EQUIPMENT....4117
HANDLING HYDRAULIC QUICK COUPLER....4119
WORK POSSIBLE USING WHEEL LOADER....4123
PRECAUTIONS FOR OPERATION....4128
ADJUSTING WORK EQUIPMENT POSTURE....4130
PARKING MACHINE....4133
CHECKS AFTER COMPLETION OF OPERATION....4135
LOCKING....4135
HANDLING THE TIRES....4136
TRANSPORTATION....4138
TRANSPORTATION PROCEDURE....4138
LOADING, UNLOADING WORK WITH TRAILERS....4138
LIFTING MACHINE....4142
COLD WEATHER OPERATION....4144
PRECAUTIONS FOR LOW TEMPERATURE....4144
PRECAUTIONS AFTER COMPLETION OF WORK....4145
AFTER COLD WEATHER....4145
LONG-TERM STORAGE....4146
BEFORE STORAGE....4146
DURING STORAGE....4146
AFTER STORAGE....4146
TROUBLESHOOTING....4147
WHEN MACHINE RUNS OUT OF FUEL....4147
METHOD OF TOWING MACHINE....4147
IF BATTERY IS DISCHARGED....4149
OTHER TROUBLE....4152
MAINTENANCE....4157
GUIDES TO MAINTENANCE....4158
OUTLINES OF SERVICE....4160
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....4160
OUTLINE OF ELECTRIC SYSTEM....4163
WEAR PARTS....4164
WEAR PARTS LIST....4164
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....4165
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....4166
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....4167
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....4168
TORQUE LIST....4168
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....4169
MAINTENANCE SCHEDULE CHART....4170
MAINTENANCE SCHEDULE CHART....4170
SERVICE PROCEDURE....4172
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)....4172
INITIAL 250 HOURS SERVICE....4172
INITIAL 1000 HOURS SERVICE....4172
WHEN REQUIRED....4173
CHECK BEFORE STARTING....4198
EVERY 50 HOURS SERVICE....4199
EVERY 100 HOURS SERVICE....4200
EVERY 250 HOURS SERVICE....4203
EVERY 500 HOURS SERVICE....4209
EVERY 1000 HOURS SERVICE....4213
EVERY 2000 HOURS SERVICE....4219
EVERY 4000 HOURS SERVICE....4225
EVERY 8000 HOURS SERVICE....4227
SPECIFICATIONS....4229
SPECIFICATIONS....4230
ATTACHMENTS, OPTIONS....4233
SELECTING BUCKET AND TIRES....4234
HANDLING FORK TOOL....4235
EXPLANATION OF COMPONENTS....4235
OPERATION....4236
METHOD OF USING 3 LEVERS....4239
EXPLANATION OF COMPONENTS....4239
HANDLING MACHINES EQUIPPED WITH KOMTRAX....4241
BASIC PRECAUTIONS....4241
INDEX....4243
TEN00410-00 - Wheel Loader WA320PZ-6 Operation & Maintenance Manual....4247
COVER....4247
FOREWORD....4248
BEFORE READING THIS MANUAL....4249
SAFETY INFORMATION....4250
INTRODUCTION....4251
USE OF MACHINE....4251
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....4251
VISIBILITY FROM OPERATOR'S SEAT....4251
NECESSARY INFORMATION....4252
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....4252
EPA REGULATIONS, ENGINE NUMBER PLATE....4252
POSITION OF SERVICE METER....4253
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....4253
CONTENTS....4254
SAFETY....4258
SAFETY....4259
SAFETY LABELS....4262
LOCATION OF SAFETY LABELS....4262
SAFETY LABELS....4263
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....4270
PRECAUTIONS BEFORE STARTING OPERATION....4270
PREPARATIONS FOR SAFE OPERATION....4270
FIRE PREVENTION....4272
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....4273
DO NOT GET CAUGHT IN ARTICULATING PORTION....4276
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....4276
UNAUTHORIZED MODIFICATION....4276
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....4277
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....4277
PRECAUTIONS FOR OPERATION....4278
PRECAUTIONS FOR JOBSITE....4278
STARTING ENGINE....4280
OPERATION....4283
TRANSPORTATION....4289
TOWING....4290
PRECAUTIONS FOR MAINTENANCE....4291
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....4291
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....4296
TIRES....4301
OPERATION....4304
GENERAL VIEW....4305
GENERAL VIEW OF MACHINE....4305
GENERAL VIEW OF CONTROLS AND GAUGES....4306
EXPLANATION OF COMPONENTS....4308
MACHINE MONITOR....4308
SWITCHES....4345
CONTROL LEVERS, PEDALS....4359
STEERING TILT LOCK LEVER....4364
CAP AND COVER WITH LOCK....4364
FRAME LOCK BAR....4365
TOWING PIN....4366
GREASE PUMP....4366
OPENING, CLOSING CAB DOORS, WINDOWS....4367
FUSE....4371
SLOW BLOW FUSE....4373
POWER OUTLET....4374
STORAGE BOX....4374
AM/FM RADIO-CASSETTE STEREO....4375
AIR CONDITIONER....4383
HANDLING CAB WIPER....4390
OPERATION....4391
CHECK BEFORE STARTING ENGINE, ADJUST....4391
STARTING ENGINE....4409
CHECKS AFTER STARTING ENGINE....4413
OPERATIONS AND CHECKS AFTER STARTING ENGINE....4414
STOPPING ENGINE....4417
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....4418
TURNING....4424
OPERATION OF WORK EQUIPMENT....4426
HANDLING HYDRAULIC QUICK COUPLER....4428
WORK POSSIBLE USING WHEEL LOADER....4432
PRECAUTIONS FOR OPERATION....4437
ADJUSTING WORK EQUIPMENT POSTURE....4439
PARKING MACHINE....4442
CHECKS AFTER COMPLETION OF OPERATION....4444
LOCKING....4444
HANDLING THE TIRES....4445
TRANSPORTATION....4447
TRANSPORTATION PROCEDURE....4447
LOADING, UNLOADING WORK WITH TRAILERS....4447
LIFTING MACHINE....4451
COLD WEATHER OPERATION....4453
PRECAUTIONS FOR LOW TEMPERATURE....4453
PRECAUTIONS AFTER COMPLETION OF WORK....4454
AFTER COLD WEATHER....4454
LONG-TERM STORAGE....4455
BEFORE STORAGE....4455
DURING STORAGE....4455
AFTER STORAGE....4455
TROUBLESHOOTING....4456
WHEN MACHINE RUNS OUT OF FUEL....4456
METHOD OF TOWING MACHINE....4456
IF BATTERY IS DISCHARGED....4458
OTHER TROUBLE....4461
MAINTENANCE....4466
GUIDES TO MAINTENANCE....4467
OUTLINES OF SERVICE....4469
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....4469
OUTLINE OF ELECTRIC SYSTEM....4472
WEAR PARTS....4473
WEAR PARTS LIST....4473
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....4474
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....4475
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....4476
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....4477
TORQUE LIST....4477
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....4478
MAINTENANCE SCHEDULE CHART....4479
MAINTENANCE SCHEDULE CHART....4479
SERVICE PROCEDURE....4481
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)....4481
INITIAL 250 HOURS SERVICE....4481
INITIAL 1000 HOURS SERVICE....4481
WHEN REQUIRED....4482
CHECK BEFORE STARTING....4507
EVERY 50 HOURS SERVICE....4508
EVERY 100 HOURS SERVICE....4509
EVERY 250 HOURS SERVICE....4512
EVERY 500 HOURS SERVICE....4518
EVERY 1000 HOURS SERVICE....4522
EVERY 2000 HOURS SERVICE....4528
EVERY 4000 HOURS SERVICE....4534
EVERY 8000 HOURS SERVICE....4536
SPECIFICATIONS....4538
SPECIFICATIONS....4539
ATTACHMENTS, OPTIONS....4542
SELECTING BUCKET AND TIRES....4543
HANDLING FORK TOOL....4544
EXPLANATION OF COMPONENTS....4544
OPERATION....4545
METHOD OF USING 3 LEVERS....4548
EXPLANATION OF COMPONENTS....4548
HANDLING MACHINES EQUIPPED WITH KOMTRAX....4550
BASIC PRECAUTIONS....4550
INDEX....4552
TEN00459-01 - Wheel Loader WA320PZ-6 Operation & Maintenance Manual....4556
COVER....4556
FOREWORD....4557
BEFORE READING THIS MANUAL....4558
SAFETY INFORMATION....4559
INTRODUCTION....4560
USE OF MACHINE....4560
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE....4560
VISIBILITY FROM OPERATOR'S SEAT....4560
NECESSARY INFORMATION....4561
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE....4561
EPA REGULATIONS, ENGINE NUMBER PLATE....4561
POSITION OF SERVICE METER....4562
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR....4562
CONTENTS....4563
SAFETY....4567
SAFETY....4568
SAFETY LABELS....4571
LOCATION OF SAFETY LABELS....4571
SAFETY LABELS....4572
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE....4579
PRECAUTIONS BEFORE STARTING OPERATION....4579
PREPARATIONS FOR SAFE OPERATION....4579
FIRE PREVENTION....4581
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE....4582
DO NOT GET CAUGHT IN ARTICULATING PORTION....4585
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES....4585
UNAUTHORIZED MODIFICATION....4585
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS....4586
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING....4586
PRECAUTIONS FOR OPERATION....4587
PRECAUTIONS FOR JOBSITE....4587
STARTING ENGINE....4589
OPERATION....4592
TRANSPORTATION....4598
TOWING....4599
PRECAUTIONS FOR MAINTENANCE....4600
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE....4600
PRECAUTIONS FOR INSPECTION AND MAINTENANCE....4605
TIRES....4610
OPERATION....4613
GENERAL VIEW....4614
GENERAL VIEW OF MACHINE....4614
GENERAL VIEW OF CONTROLS AND GAUGES....4615
EXPLANATION OF COMPONENTS....4617
MACHINE MONITOR....4617
SWITCHES....4654
CONTROL LEVERS, PEDALS....4668
STEERING TILT LOCK LEVER....4673
CAP AND COVER WITH LOCK....4673
FRAME LOCK BAR....4674
TOWING PIN....4675
GREASE PUMP....4675
OPENING, CLOSING CAB DOORS, WINDOWS....4676
FUSE....4680
SLOW BLOW FUSE....4682
POWER OUTLET....4683
STORAGE BOX....4683
AM/FM RADIO-CASSETTE STEREO....4684
AIR CONDITIONER....4692
HANDLING CAB WIPER....4699
OPERATION....4700
CHECK BEFORE STARTING ENGINE, ADJUST....4700
STARTING ENGINE....4718
CHECKS AFTER STARTING ENGINE....4722
OPERATIONS AND CHECKS AFTER STARTING ENGINE....4723
STOPPING ENGINE....4726
MOVING THE MACHINE (DIRECTIONAL, SPEED), STOPPING THE MACHINE....4727
TURNING....4733
OPERATION OF WORK EQUIPMENT....4735
HANDLING HYDRAULIC QUICK COUPLER....4737
WORK POSSIBLE USING WHEEL LOADER....4741
PRECAUTIONS FOR OPERATION....4746
ADJUSTING WORK EQUIPMENT POSTURE....4748
PARKING MACHINE....4751
CHECKS AFTER COMPLETION OF OPERATION....4753
LOCKING....4753
HANDLING THE TIRES....4754
TRANSPORTATION....4756
TRANSPORTATION PROCEDURE....4756
LOADING, UNLOADING WORK WITH TRAILERS....4756
LIFTING MACHINE....4760
COLD WEATHER OPERATION....4762
PRECAUTIONS FOR LOW TEMPERATURE....4762
PRECAUTIONS AFTER COMPLETION OF WORK....4763
AFTER COLD WEATHER....4763
LONG-TERM STORAGE....4764
BEFORE STORAGE....4764
DURING STORAGE....4764
AFTER STORAGE....4764
TROUBLESHOOTING....4765
WHEN MACHINE RUNS OUT OF FUEL....4765
METHOD OF TOWING MACHINE....4765
IF BATTERY IS DISCHARGED....4767
OTHER TROUBLE....4770
MAINTENANCE....4775
GUIDES TO MAINTENANCE....4776
OUTLINES OF SERVICE....4778
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC....4778
OUTLINE OF ELECTRIC SYSTEM....4781
WEAR PARTS....4782
WEAR PARTS LIST....4782
RECOMMENDED FUEL, COOLANT, AND LUBRICANT....4783
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....4784
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL....4785
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS....4786
TORQUE LIST....4786
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....4787
MAINTENANCE SCHEDULE CHART....4788
MAINTENANCE SCHEDULE CHART....4788
SERVICE PROCEDURE....4790
INITIAL 10 HOURS SERVICE (SERVICE FOR FIRST 50 HOURS ON NEW MACHINE)....4790
INITIAL 250 HOURS SERVICE....4790
INITIAL 1000 HOURS SERVICE....4790
WHEN REQUIRED....4791
CHECK BEFORE STARTING....4816
EVERY 50 HOURS SERVICE....4817
EVERY 100 HOURS SERVICE....4818
EVERY 250 HOURS SERVICE....4821
EVERY 500 HOURS SERVICE....4827
EVERY 1000 HOURS SERVICE....4831
EVERY 2000 HOURS SERVICE....4837
EVERY 4000 HOURS SERVICE....4843
EVERY 8000 HOURS SERVICE....4845
SPECIFICATIONS....4847
SPECIFICATIONS....4848
ATTACHMENTS, OPTIONS....4851
SELECTING BUCKET AND TIRES....4852
HANDLING FORK TOOL....4853
EXPLANATION OF COMPONENTS....4853
OPERATION....4854
METHOD OF USING 3 LEVERS....4857
EXPLANATION OF COMPONENTS....4857
HANDLING MACHINES EQUIPPED WITH KOMTRAX....4859
BASIC PRECAUTIONS....4859
INDEX....4861
VEBM620100 - Wheel Loader WA320-6, WA320-PZ6 Shop Manual....4865
VEBM620100....4865
00 Index and foreword....4867
100 Index....4867
Composition of shop manual....4868
Table of contents....4870
200 Foreword and general information....4879
Safety notice....4880
How to read the shop manual....4885
Explanation of terms for maintenance standard....4887
Handling of electric equipment and hydraulic component....4889
Handling of connectors newly used for engines....4898
How to read electric wire code....4901
Precautions when carrying out operation....4904
Method of disassembling and connecting push-pull type coupler....4907
Standard tightening torque table....4910
Conversion table....4914
01 Specification....4919
100 Specification and technical data....4919
Specification dimension drawing....4921
Specifications....4922
Weight table....4927
Table of fuel, coolant and lubricants....4929
10 Structure, function and maintenance standard....4931
100 Engine and cooling system....4931
Engine mount and transfer mount....4932
Damper....4933
Cooling system....4934
Cooling system hydraulic piping diagram....4935
Cooling fan motor....4937
200 Power train....4945
Power train....4947
Power train system diagram....4948
Drive shaft....4950
HST hydraulic piping diagram....4951
HST pump....4952
HST motor....4960
Transfer....4966
Clutch solenoid valve....4977
Axle....4978
Differential....4980
Torque proportioning differential....4985
Limited slip differential....4988
Final drive....4992
300 Steering system....4997
Steering piping diagram....4999
Steering column....5000
Priority valve....5001
Orbit-roll valve....5004
Cushion valve....5012
Steering cylinder....5013
Emergency steering piping diagram....5015
Emergency steering valve....5016
Steering relief valve....5019
400 Brake system....5021
Brake piping diagram....5023
Charge valve....5024
Brake valve....5028
Inching valve....5032
Accumulator (for brake)....5033
Slack adjuster....5034
Brake....5036
Parking brake control....5041
Parking brake....5042
500 Undercarriage and frame....5043
Axle mount and center hinge pin....5044
Tires....5049
600 Hydraulic system....5051
Work equipment hydraulic piping diagram....5052
Work equipment control lever linkage....5056
Hydraulic tank....5060
4-gear pump....5062
Work equipment control valve....5064
Cut-off valve....5090
PPC valve....5093
Lock valve....5107
Accumulator (for PPC circuit)....5108
Quick coupler solenoid valve....5109
ECSS valve....5110
Accumulator (for ECSS)....5112
700 Work equipment....5113
Work equipment linkage....5114
Bucket....5118
Bucket positioner and boom kick-out....5122
Work equipment cylinder....5134
800 Cab and its attachments....5137
Cab....5139
Air conditioner....5140
910 Electrical system, Part 1....5153
Machine monitor system....5154
Machine monitor....5158
920 Electrical system, Part 2....5179
Electrical system (HST controller system)....5180
HST controller....5196
ECSS system....5198
KOMTRAX system....5200
Engine starting circuit....5202
Engine stopping circuit....5204
Preheating circuit....5205
Engine output derating function....5206
Automatic warm-up function....5206
Parking brake circuit....5208
Coupler plunger control system....5210
Max. traction switch....5211
Multi-function knob....5212
Sensor....5213
20 Standard value table....5221
100 Standard service value table....5221
Standard service value table for engine....5222
Standard service value table for chassis....5223
30 Testing and adjusting....5229
110 Testing and adjusting, Part 1....5229
Tools for testing, adjusting, and troubleshooting....5231
Measuring engine speed....5236
Measuring exhaust gas color....5238
Adjusting valve clearance....5240
Measuring compression pressure....5242
Measuring blow-by pressure....5245
Measuring engine oil pressure....5246
Measuring intake air (boost) pressure....5247
Handling fuel system equipment....5249
Releasing residual pressure in fuel system....5249
Measuring fuel pressure....5250
Measuring fuel return rate and leakage....5252
Bleeding air from fuel circuit....5256
Checking leakage in fuel system....5257
Handling cylinder cut-out mode operation....5258
Handling no-injection cranking operation....5258
Handling controller voltage circuit....5259
Check of muffler and muffler stack for looseness and damage....5259
Check of muffler function....5260
Check of installed condition of cylinder head and manifolds....5260
Check of engine piping for damage and looseness....5261
Testing and adjusting air conditioner compressor belt tension....5261
Replacing alternator belt....5262
120 Testing and adjusting, Part 2....5263
Checking operating force of accelerator pedal....5265
Checking directional lever....5266
Testing and adjusting HST oil pressure....5267
Testing clutch control pressure....5271
Testing and adjusting steering wheel....5272
Testing and adjusting steering oil pressure....5274
Bleeding air from steering circuit....5276
Testing hydraulic fan....5277
Measuring brake pedal....5279
Testing and adjusting brake pedal linkage....5280
Measuring brake performance....5281
Testing and adjusting accumulator charge pressure....5282
Testing wheel brake oil pressure....5284
Testing wear of brake disc....5287
Bleeding air from wheel brake circuit....5288
Releasing residual pressure in brake accumulator circuit....5289
Testing parking brake performance....5290
Testing and adjusting parking brake control cable....5291
Measuring and adjusting work equipment control lever....5292
Testing and adjusting work equipment hydraulic pressure....5293
Testing work equipment PPC oil pressure....5294
Bleeding air from hydraulic circuit....5296
Releasing remaining pressure in hydraulic circuit....5297
Testing and adjusting bucket positioner....5298
Testing and adjusting of boom kick-out switch....5299
Checking proximity switch operation pilot lamp....5300
Procedure for testing diodes....5301
Preparation work for troubleshooting for electric system....5302
Starting KOMTRAX terminal operations....5306
Indicator lamps of KOMTRAX terminal....5310
130 Testing and adjusting, Part 3....5313
Adjusting machine monitor....5314
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor....5315
Special functions of machine monitor (EMMS)....5317
Pm clinic inspection chart....5370
40 Troubleshooting....5373
100 Failure code table and fuse locations....5373
Failure codes table....5374
Fuse locations....5380
200 General information on troubleshooting....5383
Points to remember when troubleshooting....5384
Sequence of events in troubleshooting....5385
Testing before troubleshooting....5386
Classification and procedures of troubleshooting....5387
Information contained in troubleshooting table....5390
Connection table for connector pin numbers....5392
T- branch box and T- branch adapter table....5428
310 Troubleshooting by failure code (Display of code), Part 1....5431
Failure code [2G40ZG] Brake: Oil pressure reduction....5432
Failure code [6091NX] HST filter: Clogging....5434
Failure code [989FN1] Travel speed: Overrun alarm....5435
Failure code [AA1ANX] Air cleaner: Clogging....5436
Failure code [AB00L6] Alternator R system: Hot short....5438
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/ Low charge voltage....5440
Failure code [B@BAZG] Engine: Oil pressure reduction....5442
Failure code [B@BAZK] Engine oil: Low level....5443
Failure code [B@BCNS] Engine: Overheat....5444
Failure code [B@BCZK] Engine: Low coolant level....5446
Failure code [B@C6NS] Front brake: High oil temperature....5448
Failure code [B@CRNS] HST: High oil temperature....5449
320 Troubleshooting by failure code (Display of code), Part 2....5451
Failure code [CA111] Abnormality in engine controller....5453
Failure code [CA115] Engine Ne or Bkup speed sensor error....5454
Failure code [CA122] Charge pressure sensor high error....5456
Failure code [CA123] Charge pressure sensor low error....5458
Failure code [CA131] Throttle sensor high error....5460
Failure code [CA132] Throttle sensor low error....5462
Failure code [CA144] Coolant sensor high error....5464
Failure code [CA145] Coolant sensor low error....5466
Failure code [CA153] Charge temperature sensor high error....5468
Failure code [CA154] Charge temperature sensor low error....5470
Failure code [CA155] Derating of speed by abnormally high charge temperature....5472
Failure code [CA187] Sensor power supply 2 low error....5474
Failure code [CA221] Atmospheric pressure sensor high error....5476
Failure code [CA222] Atmospheric sensor low error....5478
Failure code [CA227] Sensor power supply 2 high error....5480
Failure code [CA234] Engine overspeed....5481
Failure code [CA238] Ne speed sensor power supply error....5482
Failure code [CA271] IMV (IMA) Short circuit....5483
Failure code [CA272] IMV (IMA) Disconnection....5484
Failure code [CA322] Injector #1 open/short error....5486
Failure code [CA323] Injector #5 open/short error....5488
Failure code [CA324] Injector #3 open/short error....5490
Failure code [CA325] Injector #6 open/short error....5492
Failure code [CA331] Injector #2 open/short error....5494
Failure code [CA332] Injector #4 open/short error....5496
Failure code [CA342] Calibration code inconsistency....5498
Failure code [CA351] Injectors drive circuit error....5500
Failure code [CA352] Sensor power supply 1 low error....5502
Failure code [CA386] Sensor power supply 1 high error....5504
330 Troubleshooting by failure code (Display of code), Part 3....5505
Failure code [CA428] Abnormally high level in water sensor....5508
Failure code [CA429] Abnormally low level in water sensor....5510
Failure code [CA431] Idle validation switch error....5512
Failure code [CA432] Idle validation action error....5516
Failure code [CA435] Engine oil pressure switch error....5520
Failure code [CA441] Battery voltage low error....5521
Failure code [CA442] Battery voltage high error....5524
Failure code [CA449] Common rail pressure high error 2....5526
Failure code [CA451] Common rail pressure sensor high error....5528
Failure code [CA452] Common rail pressure sensor low error....5530
Failure code [CA488] Derating of torque by abnormally high charge temperature....5532
Failure code [CA553] Common rail pressure high error 1....5533
Failure code [CA559] Supply pump pressure very low error....5534
Failure code [CA689] Engine Ne speed sensor error....5536
Failure code [CA731] Engine Bkup speed sensor phase error....5538
Failure code [CA757] All continuous data lost error....5539
Failure code [CA778] Engine Bkup speed sensor error....5542
Failure code [CA1633] KOMNET datalink timeout error....5544
Failure code [CA2185] Throttle sensor supply voltage high error....5548
Failure code [CA2186] Throttle sensor power supply low error....5550
Failure code [CA2249] Supply pump pressure very low error 2....5552
Failure code [CA2311] Abnormality in IMV (IMA) solenoid....5554
Failure code [CA2555] Intake heater relay disconnection error....5556
Failure code [CA2556] Intake heater relay short circuit error....5558
340 Troubleshooting by failure code (Display of code), Part 4....5561
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short....5562
Failure code [D192KY] ECSS solenoid relay: Hot short....5564
Failure code [D1B0KA] HST safety relay: Disconnection....5566
Failure code [D1B0KB] HST safety relay: Ground fault....5568
Failure code [D1B0KY] HST safety relay: Hot short....5570
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection....5572
Failure code [DAF3KK] UNSW power supply: Ground fault/ Disconnection....5574
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection....5576
Failure code [DAJ0KK] HST controller power supply: Low voltage....5580
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality....5582
Failure code [DAJ1L4] HST controller main power line: Disconnection/ Ground fault....5584
Failure code [DAJ1L6] HST controller main power line: Hot short....5586
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage....5588
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness....5590
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault....5592
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range....5594
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals....5596
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection....5597
Failure code [DAJRMA] HST controller: Disagreement in option selection....5603
350 Troubleshooting by failure code (Display of code), Part 5....5605
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line....5606
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality....5612
Failure code [DD1NLD] Fan reverse switch signal: Abnormality....5614
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/ Hot short....5616
Failure code [DDB6KB] Parking brake indicator signal: Ground fault....5618
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch (intermediate switch): Trouble....5620
Failure code [DDB6L0] Parking brake reminder signal: Ground fault....5622
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/ Hot short....5624
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/ Ground fault....5626
Failure code [DDD7KY] Travel speed control dial signal: Hot short....5628
Failure code [DDE5MA] Emergency steering operation switch: Disconnection....5630
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault....5632
Failure code [DDK6KY] FNR lever: Hot short....5636
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)....5638
360 Troubleshooting by failure code (Display of code), Part 6....5641
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault....5642
Failure code [DF10KB] Travel speed range selector switch: Hot short....5646
Failure code [DGH1KX] HST oil temperature sensor: Ground fault....5648
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault....5649
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/ Hot short....5650
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault....5652
Failure code [DHH1KY] HST oil pressure sensor: Hot short....5654
Failure code [DHTCL6] HST filter clogging sensor: Functional defect....5656
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short....5658
Failure code [DLT3KX] Travel speed sensor B: Abnormality....5660
Failure code [DLT4KX] Travel speed sensor A: Abnormality....5664
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality....5666
Failure code [DV00KY] Alarm buzzer: Hot short....5668
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault....5670
Failure code [DW26KY] Motor 2 solenoid: Hot short....5672
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short....5674
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/ Ground fault....5676
370 Troubleshooting by failure code (Display of code), Part 7....5679
Failure code [DX16KA] Fan EPC solenoid: Disconnection....5680
Failure code [DX16KB] Fan EPC solenoid: Ground fault....5681
Failure code [DX16KY] Fan EPC solenoid: Hot short....5682
Failure code [DX19KA] Motor 1 solenoid: Disconnection....5684
Failure code [DX19KB] Motor 1 solenoid: Ground fault....5686
Failure code [DX19KY] Motor 1 solenoid: Hot short....5688
Failure code [DX20KA] Clutch EPC solenoid: Disconnection....5690
Failure code [DX20KB] Clutch EPC solenoid: Ground fault....5692
Failure code [DX20KY] Clutch EPC solenoid: Hot short....5694
Failure code [DXH7KB] Reverse solenoid: Ground fault....5696
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short....5698
Failure code [DXH8KB] Forward solenoid: Ground fault....5700
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short....5702
Failure code [J141N1] Steering pump: Overrun alarm....5704
Failure code [M100N1] HST pump: Overrun alarm....5704
Failure code [M400N1] Motor 1: Overrun alarm....5705
400 Troubleshooting of electrical system (E-mode)....5707
E-1 Engine does not start....5709
E-2 Preheater does not operate normally....5716
E-3 Travel speed is low or high....5720
E-4 ECSS does not operate....5726
E-5 ECSS keeps operating....5729
E-6 Defective boom kick-out function and cancellation....5732
E-7 Defective bucket positioner function and cancellation....5736
E-8 Defective lift arm FLOATING holding function and cancellation....5740
E-9 Travel direction selection system does not function....5744
E-10 Fan does not reverse....5748
E-11 Fan keeps rotating in reverse....5752
E-12 Wiper does not operate....5754
E-13 Windshield washer does not operate....5758
E-14 Headlamp, clearance lamp and tail lamp do not light up or go off....5762
E-15 Working lamp does not light up or go off....5770
E-16 Turn signal lamp and hazard lamp do not light up or go off....5776
E-17 Brake lamp does not light or it keeps lighting up....5782
E-18 Backup lamp does not light or it keeps lighting up....5784
E-19 Backup alarm does not sound or it keeps sounding....5787
E-20 Horn does not sound or it keeps sounding....5790
E-21 Alarm buzzer does not sound or it keeps sounding....5792
E-22 Air conditioner does not operate or stop....5794
E-23 The KOMTRAX system does not work properly....5797
500 Troubleshooting of hydraulic and mechanical system (H-mode)....5801
Method of using troubleshooting chart....5803
Failure code and cause table....5806
H-1 The machine does not start....5808
H-2 The travel speed is slow....5809
H-3 The traction force is weak....5810
H-4 Engine stalls when traveling or engine speed drops excessively....5811
H-5 Shift range is not shifted....5812
H-6 The steering wheel does not turn....5813
H-7 The steering wheel is heavy....5814
H-8 Steering wheel shakes or jerks....5815
H-9 Machine deviates naturally to one side when traveling....5815
H-10 The brake does not work or does not work well....5816
H-11 The brake is not released or is dragged....5817
H-12 The lift arm does not rise or lower....5818
H-13 The lift arm moves slowly or the lift arm rising force is insufficient....5819
H-14 When rising, the lift arm comes to move slowly at specific height....5820
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)....5820
H-16 Hydraulic drifts of the lift arm occur often....5820
H-17 The lift arm wobbles during operation....5820
H-18 When the control lever is switched from “HOLD” to “RAISE,” the lift arm falls temporarily....5821
H-19 The bucket does not tilt back....5822
H-20 The bucket moves slowly or the tilting-back force is insufficient....5823
H-21 The bucket comes to operate slowly in the midst of tilting-back....5824
H-22 The bucket cylinder cannot hold down the bucket....5824
H-23 Hydraulic drifts of the bucket occur often....5824
H-24 The bucket wobbles during travel with load (The work equipment valve is set to “HOLD”)....5824
H-25 When the control lever is switched from “HOLD” to “TILT,” the bucket falls temporarily....5825
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy....5825
H-27 The ECSS does not operate and machine pitches and bounces....5826
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)....5827
600 Troubleshooting of engine (S-mode)....5829
Method of using troubleshooting charts....5830
S-1 Starting performance is poor....5834
S-2 Engine does not start....5836
S-3 Engine does not pick up smoothly....5839
S-4 Engine stops during operations....5840
S-5 Engine does not rotate smoothly....5841
S-6 Engine lacks output (or lacks power)....5842
S-7 Exhaust smoke is black (incomplete combustion)....5843
S-8 Oil consumption is excessive (or exhaust smoke is blue)....5844
S-9 Oil becomes contaminated quickly....5845
S-10 Fuel consumption is excessive....5846
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)....5847
S-12 Oil pressure drops....5848
S-13 Oil level rises (Entry of coolant or fuel)....5849
S-14 Coolant temperature becomes too high (overheating)....5850
S-15 Abnormal noise is made....5851
S-16 Vibration is excessive....5852
50 Disassembly and assembly....5853
100 General information on disassembly and assembly....5853
How to read this manual....5854
Coating materials list....5856
Special tool list....5859
Sketches of special tools....5863
200 Engine and cooling system....5871
Removal and installation of fuel supply pump assembly....5872
Removal and installation of fuel injector assembly....5874
Removal and installation of cylinder head assembly....5882
Removal and installation of engine hood assembly....5894
Removal and installation of radiator....5897
Removal and installation of air aftercooler....5900
Removal and installation of hydraulic oil cooler assembly....5902
Removal and installation of engine assembly....5904
Removal and installation of engine front oil seal assembly....5910
Removal and installation of engine rear oil seal assembly....5913
Removal and installation of cooling fan and fan motor assembly....5916
Removal and installation of fuel tank assembly....5919
310 Power train, Part 1....5921
Removal and installation of transfer assembly....5922
Disassembly and assembly of transfer assembly....5925
Removal and installation of parking brake assembly....5944
Disassembly and assembly of parking brake assembly....5945
320 Power train, Part 2....5951
Removal and installation of front axle assembly....5952
Removal and installation of rear axle assembly....5954
Disassembly and assembly of axle housing assembly....5957
Disassembly and assembly of differential assembly....5969
400 Undercarriage and frame....5993
Removal and installation of center hinge pin....5994
Removal and installation of counterweight assembly....6004
500 Hydraulic system....6007
Removal and installation of HST pump and 4-gear pump assembly....6008
Disassembly and assembly of HST pump assembly....6011
Removal and installation of HST motor 1 assembly....6038
Removal and installation of HST motor 2 assembly....6040
Disassembly and assembly of HST motor assembly....6042
Removal and installation of work equipment control valve assembly....6058
Removal and installation of hydraulic tank assembly....6060
Disassembly and assembly of hydraulic cylinder assembly....6062
600 Work equipment....6069
Removal and installation of work equipment assembly....6070
700 Cab and its attachments....6077
Removal and installation of operator's cab and floor frame assembly....6078
Removal and installation of operator's cab glass (Stuck glass)....6084
Disassembly and assembly of operator's seat assembly....6092
Removal and installation of air conditioner unit....6102
800 Electrical system....6107
Removal and installation of monitor panel....6108
Removal and installation of engine controller assembly....6110
Removal and installation of HST controller assembly....6111
Removal and installation of KOMTRAX terminal assembly....6112
90 Diagrams and drawings....6113
100 Hydraulic diagrams and drawings....6113
Central lubrication system....6114
Hydraulic circuit diagram WA320-6....6115
Hydraulic circuit diagram WA320PZ-6....6116
200 Electrical diagrams and drawings....6117
Electrical circuit diagram (1/9)....6119
Electrical circuit diagram (2/9)....6120
Electrical circuit diagram (3/9)....6121
Electrical circuit diagram (4/9)....6122
Electrical circuit diagram (5/9)....6123
Electrical circuit diagram (6/9)....6124
Electrical circuit diagram (7/9)....6125
Electrical circuit diagram (8/9)....6126
Electrical circuit diagram (9/9)....6127
Specific electrical circuit diagram (1/4)....6128
Specific electrical circuit diagram (2/4)....6129
Specific electrical circuit diagram (3/4)....6130
Specific electrical circuit diagram (4/4)....6131
Connector list and stereogram....6132
Komatsu Wheel Loader WA320, WA320PZ Repair Service Manual
