Komatsu Wheel Loader WA320-7 Japan sn:80001 and up Workshop Service Manual

Original Illustrated Factory Workshop Service Manual for Komatsu Wheel Loader WA320. 
Original factory manuals for Komatsu Loaders, Dozers, Excavators contains high quality images, circuit diagrams and instructions to help you to operate, maintenance and repair your truck. All Manuals Printable, contains Searchable Text and Navigation Bookmarks
 
Covered models:
    WA320-7 Japan sn:80001 and up
 
Format: PDF, 2052 Pages
Language: English
 
Contents:
    00 Index and foreword
    01 Specification
        Specifications
        Specification drawing 
        Specifications 
        Weight table 
        Table of fuel, coolant, and lubricants 
    10 Structure and function .
        Table of contents 
        Engine and cooling system
        Engine related parts 
        KVGT
        EGR system piping drawing 
        EGR system circuit diagram
        EGR valve
        EGR cooler
        KCCV layout drawing 
        KCCV ventilator 
        KDPF
        Cooling system 
        Cooling fan motor
        Power train
        Power train system
        Layout of power train parts
        Damper 
        HST pump
        HST motor1 
        HST motor2 
        Transfer 
        Clutch solenoid valve 
        Drive shaft
        Axle 
        Differential
        Torque proportional differential 
        Limited slip differential 
        Final drive 
        Steering system
        Layout of steering devices 
        Steering column
        Priority valve
        Cushion valve
        Emergency steering valve
        Orbitrol valve 
        Brake system 
        Layout of brake parts
        Brake accumulator charge valve
        Brake valve 
        Brake accumulator 
        Slack adjuster 
        Brake 
        Parking brake control 
        Parking brake 
        Parking brake solenoid valve 
        Undercarriage and frame
        Axle mount 
        Center hinge pin 
        Tire 
        Hydraulic system 
        Hydraulic component layout
        Work equipment control 
        Hydraulic tank
        Double type gear pump 
        Steering and work equipment pump
        Control valve 
        CLSS
        Hydraulic circuit diagram and names of valves
        Self-pressure reducing valve
        Work equipment PPC valve 
        Work equipment lock solenoid valve 
        PPC circuit accumulator 
        ECSS accumulator
        Work equipment 
        Work equipment linkage 
        Bucket 
        Cab and its attachments 
        ROPS cab 
        Cab mount 
        Electrical system 
        Engine control system 
        Preheating system 
        Engine output limit function 
        Automatic warm-up function
        Parking brake control system 
        System operating lamp function
        Battery disconnect switch function 
        HST controller system
        Machine monitor system
        Rearview monitor system
        KOMTRAX system
        System component parts 
        Sensor 
    20 Standard value tables
        Table of contents 
        Standard service value table
            Standard value table for engine 
            Standard value table for machine 
            Standard value table for electrical system.
    30 Testing and adjusting .
        Table of contents 
        Related information on testing and adjusting 
        Tools for testing and adjusting 
        Sketch of tools for testing and adjusting 
        Engine and cooling system
        Testing engine speed 
        Testing boost pressure 
        Testing exhaust gas temperature
        Testing exhaust gas color 
        Testing and adjusting valve clearance 
        Testing compression pressure
        Testing blowby pressure 
        Testing engine oil pressure 
        Testing EGR valve and KVGT driving oil pressure
        Testing fuel pressure 
        Testing fuel discharge, return and leakage
        Bleeding air from fuel system 
        Testing fuel circuit for leakage 
        Handling cylinder cutout mode operation
        Handling no-injection cranking operation
        Testing of KDPF and muffler stack for looseness and damage 
        Testing of installed condition of cylinder heads and manifolds 
        Testing engine piping for damage and looseness 
        Testing and adjusting air conditioner compressor belt tension 
        Replacing alternator belt 
        Power train
        Testing oil leakage from axle final drive 
        Testing drive shaft for looseness, backlash, and damage
        Testing accelerator pedal 
        Testing and adjusting HST oil pressure
        Testing transfer clutch control pressure 
        Steering system
        Testing directional lever 
        Testing steering wheel 
        Testing work equipment control lever 
        Testing and adjusting steering circuit oil pressure
        Bleeding air from steering cylinder circuit 
        Brake system 
        Testing brake pedal 
        Testing braking performance 
        Testing and adjusting of accumulator charge pressure
        Testing wheel brake oil pressure
        Testing lowering of wheel brake pressure 
        Testing wear of wheel brake disc 
        Bleeding air from wheel brake circuit
        Releasing remaining pressure in brake accumulator circuit 
        Testing parking brake performance 
        Testing wear of parking brake disc 
        Testing parking brake release pressure 
        Method of releasing parking brake manually 
        Hydraulic system 
        Testing cooling fan speed 
        Testing cooling fan pump circuit oil pressure 
        Bleeding air from hydraulic fan circuit
        Testing and adjusting work equipment PPC oil pressure 
        Testing and adjusting work equipment oil pressure
        Bleeding air from work equipment circuit 
        Releasing remaining pressure from work equipment circuit
        Testing ECSS accumulator nitrogen gas pressure and procedure for charging accumulator with nitrogen gas 
        Work equipment 
        Testing and adjusting bucket positioner and bucket proximity switch
        Testing and adjusting boom position detection lever 
        Electrical system 
        Adjusting replaced, reassembled or added sensor, controller, etcwith machine
        monitor 
        Special functions of machine monitor 
        Adjusting rearview camera angle
        Handling voltage circuit of engine controller 
        Handling battery disconnect switch
        Testing diodes 
        Pm clinic 
        Pm Clinic service 
        Check sheet 
    40 Troubleshooting.
        Table of contents 
        Related information on troubleshooting
        Troubleshooting points 
        Sequence of events in troubleshooting
        Checks before troubleshooting
        Inspection procedure before troubleshooting 
        Preparation for troubleshooting of electrical system
        Classification and procedures for troubleshooting 
        Symptom and troubleshooting numbers 
        Information in troubleshooting table 
        Procedure for troubleshooting wiring harness of pressure sensor system for open circuit
        Connector list and layout 
        Connector contact identification
        T-branch box and T-branch adapter table 
        Fuse location table 
        Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 
        Precautions when performing troubleshooting of machine monitor
        Processing procedure of harness checker for troubleshooting of machine monitor LCD unit 
        Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors)
        Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) 
        Failure codes table
        Troubleshooting by failure code (Display of code) 
        Troubleshooting of electrical system (E-mode) 
        Troubleshooting of hydraulic and mechanical system (H-mode) 
        Troubleshooting of engine (S-mode).
    50 Disassembly and assembly .
        Table of contents 
        Related information on disassembly and assembly 
        How to read this manual 
        Coating materials list 
        Special tools list 
        Sketches of special tools 
        Engine and cooling system
        Removal and installation of supply pump assembly
        Removal and installation of injector assembly
        Removal and installation of cylinder head assembly
        Removal and installation of engine hood assembly 
        Removal and installation of radiator core assembly 
        Removal and installation of aftercooler
        Removal and installation of hydraulic oil cooler 
        Removal and installation of engine assembly 
        Removal and installation of engine front oil seal 
        Removal and installation of engine rear oil seal
        Removal and installation of cooling fan and fan motor assembly 
        Removal and installation of KDPF assembly
        Disassembly and assembly of KDPF assembly 
        Removal and installation of KCCV assembly 
        Removal and installation of air cleaner assembly 
        Removal and installation of KVGT assembly
        Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly
        Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly
        Removal and installation of alternator belt 
        Removal and installation of fuel tank assembly 
        Power train
        Removal and installation of transfer assembly 
        Disassembly and assembly of transfer assembly 
        Removal and installation of front axle assembly 
        Removal and installation of rear axle assembly
        Disassembly and assembly of axle housing assembly
        Disassembly and assembly of differential assembly 
        Undercarriage and frame
        Removal and installation of center hinge pin 
        Removal and installation of counterweight assembly 
        Hydraulic system 
        Removal and installation of hydraulic tank assembly 
        Removal and installation of control valve assembly 
        Disassembly and assembly of control valve assembly
        Removal and installation of hydraulic pump assembly 
        Removal and installation of HST motor1 assembly
        Removal and installation of HST motor2 assembly
        Disassembly and assembly of hydraulic cylinder assembly
        Work equipment 
        Removal and installation of work equipment assembly 
        Cab and its attachments 
        Removal and installation of operator's cab and floor frame assembly
        Removal and installation of operator's cab glass (adhered glass) 
        Removal and installation of operator's seat assembly
        Removal and installation of seat belt
        Removal and installation of air conditioner unit assembly
        Removal and installation of air conditioner compressor 
        Removal and installation of air conditioner condenser 
        Electrical system 
        Removal and installation of machine monitor assembly 
        Removal and installation of engine controller assembly 
        Removal and installation of HST controller assembly
        Removal and installation of air conditioner controller assembly 
        Removal and installation of monitor controller assembly 
        Removal and installation of mass air flow and temperature sensor 
        Removal and installation of KOMTRAX terminal assembly .
    60 Maintenance standard.
        Table of contents 
        Engine and cooling system
        Engine related parts 
        Cooling fan motor
        Power train
        Damper 
        Transfer 
        Drive shaft
        Axle 
        Differential
        Limited slip differential 
        Final drive 
        Steering system
        Steering column
        Priority valve
        Emergency steering valve
        Steering cylinder 
        Brake system 
        Brake accumulator charge valve
        Slack adjuster 
        Brake 
        Parking brake 
        Parking brake solenoid valve 
        Undercarriage and frame
        Axle mount 
        Center hinge pin 
        Hydraulic system 
        Hydraulic tank
        Double type gear pump 
        Steering and work equipment pump
        Control valve 
        Self-pressure reducing valve
        Work equipment PPC valve 
        Work equipment lock solenoid valve 
        Work equipment 
        Work equipment linkage 
        Bucket 
        Work equipment cylinder 
        Cab and its attachments 
        Cab mount 
        Electrical system 
        Bucket positioner 
        Fork positioner 
        Remote boom positioner.
    80 Appendix.
        Table of contents 
        Air conditioner components 
        Precautions for refrigerant
        Air conditioner component 
        Configuration and function of refrigeration cycle
        Outline of refrigeration cycle
        Air conditioner unit 
        Dual pressure switch 
        Air conditioner controller 
        Compressor
        Condenser 
        Receiver drier 
        Sunlight sensor 
        Outer temperature sensor (outside air temperature sensor) 
        Procedure for testing and troubleshooting 
        Circuit diagram and arrangement of connector pins
        System diagram
        Parts and connectors layout
        Testing with self-diagnosis function 
        How to open the electrical system abnormality record screen in service mode of the machine  monitor 
        Testing temperature control system 
        Testing vent (mode) changeover
        Testing FRESH/RECIRC air changeover
        Testing evaporator temperature sensor 
        Testing relays 
        Troubleshooting chart 1 
        Troubleshooting chart 2 
        Information in troubleshooting table 
        Failure code list related to air conditioner
        Failure code [879AKA] A/C Inner Sensor Open Circuit 
        Failure code [879AKB] A/C Inner Sensor Short Circuit
        Failure code [879BKA] A/C Outer Sensor Open Circuit
        Failure code [879BKB] A/C Outer Sensor Short Circuit
        Failure code [879CKA] Ventilating Sensor Open Circuit
        Failure code [879CKB] Ventilating Sensor Short Circuit 
        Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
        Failure code [879EMC] Ventilation Damper Abnormality 
        Failure code [879FMC] Air Mix Damper Abnormality 
        A-1 Troubleshooting for power supply and CAN communication system (Air conditioner does not operate)
        A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 
        A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 
        A-4 Troubleshooting for FRESH/RECIRC air changeover 
        Troubleshooting with gauge pressure
        Connection of service tool
        Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit
        Handling of compressor oil.
    90 Diagrams and drawings.
        Table of contents 
        Hydraulic circuit diagram 
        Symbols in hydraulic circuit diagram 
        Hydraulic circuit diagram
        Electric circuit diagram 
        Symbols in electric circuit diagram
        Electrical circuit diagram of machine body 
        Electrical circuit diagram of floor .
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