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Komatsu WA320-6 Shop Manual
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Komatsu WA320-6 Shop Manual

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WA320-6
WHEEL LOADER
SERIAL NUMBERS
ENGINE
This material is proprietary to Komatsu America Corp and is not to be reproduced, used, or disclosed except in accordance
with written authorization from Komatsu America Corp.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or
add improvements at any time without incurring any obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
August 2011
Printed in USA
WA320-6
SAA6D107E-1
A35001
Copyright 2011 Komatsu
DataKom Publishing Division
CEBM022801
and UP
00-1
b

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Summary of Contents for Komatsu WA320-6

  • Page 1 SAA6D107E-1 ENGINE This material is proprietary to Komatsu America Corp and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America Corp. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously.
  • Page 2 FOREWORD CONTENTS CONTENTS GENERAL ............. 01-1 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD .
  • Page 3 10-8 10-37 00-10 00-40 10-9 10-38 00-11 00-41 10-10 10-39 00-12 00-42 10-11 10-40 00-13 ● 00-43 10-12 10-41 00-14 ● 00-44 10-13 10-42 00-15 10-14 10-43 00-16 ● 01-1 10-15 10-44 00-17 WA320-6 00-2-1 WA320-6 Find manuals at https://best-manuals.com...
  • Page 4 10-135 10-168 10-70 10-103 10-136 10-169 10-71 10-104 10-137 10-170 10-72 10-105 10-138 10-171 10-73 10-106 10-139 10-172 10-74 10-107 10-140 10-173 10-75 10-108 10-141 10-174 10-76 10-109 10-142 10-175 10-77 10-110 10-143 10-176 00-2-2 WA320-6 Find manuals at https://best-manuals.com...
  • Page 5 ● ● ❍ 10-204 10-237 10-270 10-303 ● ● ❍ 10-205 10-238 10-271 10-304 ● 10-206 10-239 10-272 ● 10-207 10-240 10-273 20-1 ● 10-208 10-241 10-274 20-2 ● ● 10-209 10-242 10-275 20-3 WA320-6 00-2-3 Find manuals at https://best-manuals.com...
  • Page 6 30-116 ● 30-18 30-51 30-84 30-117 30-19 30-52 30-85 30-118 30-20 30-53 30-86 30-119 30-21 30-54 30-87 30-120 30-22 30-55 30-88 30-121 30-23 30-56 30-89 30-122 30-24 30-57 30-90 30-123 30-25 30-58 30-91 30-124 00-2-4 WA320-6 Find manuals at https://best-manuals.com...
  • Page 7 30-151 40-23 40-56 40-89 ● 30-152 40-24 40-57 40-90 ● 30-153 40-25 40-58 40-91 ● 30-154 40-26 40-59 40-92 ● 30-155 40-27 40-60 40-93 ● 30-156 40-28 40-61 40-94 ❍ 30-157 40-29 40-62 40-95 WA320-6 00-2-5 Find manuals at https://best-manuals.com...
  • Page 8 40-186 40-219 40-121 40-154 40-187 40-220 40-122 40-155 40-188 40-221 40-123 40-156 40-189 40-222 40-124 40-157 40-190 40-223 40-125 40-158 40-191 40-224 40-126 40-159 40-192 40-225 40-127 40-160 40-193 40-226 40-128 40-161 40-194 40-227 00-2-6 WA320-6 Find manuals at https://best-manuals.com...
  • Page 9 40-318 40-351 40-286 40-319 40-352 40-253 40-254 40-287 40-320 40-353 40-255 40-288 40-321 40-354 40-256 40-289 40-322 40-355 40-257 40-290 40-323 40-356 40-258 40-291 40-324 40-357 40-259 40-292 40-325 40-358 40-260 40-293 40-326 40-359 WA320-6 00-2-7 Find manuals at https://best-manuals.com...
  • Page 10 40-450 40-483 40-385 40-418 40-451 40-484 40-386 40-419 40-452 40-485 40-387 40-420 40-453 40-486 40-388 40-421 40-454 40-487 40-389 40-422 40-455 40-488 40-390 40-423 40-456 40-489 40-391 40-424 40-457 40-490 40-392 40-425 40-458 40-491 00-2-8 WA320-6 Find manuals at https://best-manuals.com...
  • Page 11 40-516 50-32 50-65 50-98 ● 50-33 50-66 50-99 50-1 50-34 50-67 50-100 ● 50-2 50-35 50-68 50-101 50-3 50-36 50-69 50-102 50-4 50-37 50-70 50-103 ● 50-5 50-38 50-71 50-104 50-6 50-39 50-72 50-105 50-7 50-40 50-73 50-106 WA320-6 00-2-9...
  • Page 12 50-196 50-229 50-131 50-164 50-197 50-230 50-132 50-165 50-198 50-231 50-133 50-166 50-199 50-232 50-134 50-167 50-200 50-233 50-135 50-168 50-201 50-234 50-136 50-169 50-202 50-235 50-137 50-170 50-203 50-236 50-138 50-171 50-204 50-237 50-139 50-172 50-205 50-238 00-2-10 WA320-6...
  • Page 13 50-329 90-21 50-264 50-297 50-330 90-23 50-265 50-298 50-331 90-25 50-266 50-299 50-332 90-27 ❍ 50-267 50-300 50-333 90-29 ❍ 50-268 50-301 50-334 90-31 ● ❍ 50-269 50-302 50-335 ● ❍ 50-270 50-303 50-336 ❍ 50-271 50-304 50-337 WA320-6 00-2-11...
  • Page 14 FOREWORD Mark Page Mark Page Mark Page Mark Page 00-2-12 WA320-6...

  • Page 15: Safety Notice

    Always inform your fellow workers used to or work with which you are too before starting any step of the operation. Before starting familiar work, hang UNDER REPAIR signs on the controls in the operator's compartment. 00-3 b WA320-6...
  • Page 16 17. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Before starting the engine, open the windows and doors so that the area is well ventilated. 00-4 b WA320-6...

  • Page 17: Seat Belt Inspection

    The location of the “Date of Installation” label (if equipped) may vary slightly, but most frequently it will be found on the plastic molding of the seat belt. If your machine is equipped with a shoulder harness also, inspect the webbing, the shoulder loop web guide and the height adjuster for wear, damage and proper function capabilities WA320-6 00-5...
  • Page 18 Diagrams and Schematics This section has the foldout drawings for the machine. NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information. 00-6 b WA320-6...
  • Page 19 Places where oil or water must be Drain drained, and quantity to be Additional pages: Additional pages are indicated by a drained. hyphen (-) and numbered after the page number. File as in the example. Example: 10-4 10-4-1 Added pages 10-4-2 10-5 00-7 b WA320-6...

  • Page 20: Hoisting Instructions

    When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 00-8 b WA320-6...
  • Page 21 12. Remember the position of the main switch so that you ★ Read the Operation & Maintenance Manual provided can turn off the power immediately in an emergency. with the crane in advance and operate the crane safely. 00-9 b WA320-6...
  • Page 22 Do not leave the sling installed to the hook. 12.7 17.3 22.6 28.6 35.3 55.3 79.6 141.6 14.4 221.6 22.6 318.3 32.4 ★ The allowable load value is 1/6 of the breaking strength of the rope used. ★ Safety coefficient: 6 00-10 b WA320-6...
  • Page 23 SYSTEMS: ZXL100PG (equivalent to PAG46)) to its O-rings. ★ See example of O-ring in the graphic. O-rings are fitted to every joint of the hoses and tubes. ★ For the tightening torque, see the precautions for installation in the appropriate Disassembly and Assembly sections. WA320-6 00-11...
  • Page 24 (B) between the maximum size of the shaft and the minimum size of the hole is the standard interference. • After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range. 00-12 WA320-6...
  • Page 25 The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the interference limit. • The interference limit shows the repair limit of the part of smaller tolerance. • If the interference between the parts exceeds the interference limit, they must be replaced or repaired. WA320-6 00-13...
  • Page 26 The pins of the male and female connectors are in contact at the crimped terminal or soldered portion. If there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage. 00-14 WA320-6...
  • Page 27 • For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. ★ Never pull with one hand. WA320-6 00-15...
  • Page 28 ★ If there is any damage or breakage, replace the connector. 00-16 WA320-6...
  • Page 29 (2) while moving it up and down until the locks are set normally. (Arrows 1, 2, ★ Lock (a) is pulled down (not set completely) and lock (b) is set completely. • (1): Male connector • (2): Female connector • (a), (b): Locks WA320-6 00-17...
  • Page 30 Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. ★ After completely drying the connector, blow it with contact restorer and reassemble. 00-18 WA320-6...
  • Page 31 When troubleshooting circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the tester reading. ★ If there is any change, there is probably a defective contact in that circuit. WA320-6 00-19...
  • Page 32 If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 00-20 WA320-6...
  • Page 33 Intake air pressure sensor in intake manifold: PIM 125, 170, 12V140 Oil pressure sensor: POIL 95, 107, 114 Oil pressure switch 95 – 170, 12V140 Ne speed sensor of flywheel housing: NE 125, 170, 12V140 Ambient pressure sensor: PAMB WA320-6 00-21...
  • Page 34 ★ 95, 107, 114 engines Connector Sensor BOSCH0-03 Fuel pressure sensor in common rail Unplug connector (3) according to the following procedure. While pressing lock (C), pull out connector (3) in the direction of the arrow. ★ 114 engine (see graphic) 00-22 WA320-6...
  • Page 35 While pressing lock (D), pull out connector (4) in the direction of the arrow. ★ 95, 125 – 170, 12V140 engines While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Connector Sensor Fuel pressure sensor in common rail: AMP-3 PFUEL, etc. WA320-6 00-23...
  • Page 36 ★ Housing (H1) is left on the wiring harness side. Plug the connector according to the following procedure. A. Insert the connector to the end, while setting its groove. B. Turn housing (H1) in the direction of the arrow until it clicks. 00-24 WA320-6...

  • Page 37: Precautions For Operations

    07376-70210 02789-20210 07376-70315 02789-20315 07376-70422 02789-20422 07376-70522 02789-20522 07376-70628 02789-20628 07376-71034 07221-21034 07376-71234 07221-21234 • Split flange type hoses and tubes Nominal Flange (hose end) Sleeve Head (tube end) Split Flange Number 07379-00400 07378-10400 07371-30400 07379-00500 07378-10500 07371-30500 WA320-6 00-25...
  • Page 38 Next, operate the hydraulic cylinder three to four times to the end of its stroke. After doing this, run the engine at normal speed. ★ When using the machine for the first time after repair or long storage, do the same procedure. 00-26 WA320-6...
  • Page 39 Checking muffler function • Check the muffler for abnormal sound and sound different from that of a new muffler. • If any abnormal sound is heard, repair the muffler. Refer to both the “Troubleshooting” and the “Disassembly and Assembly” sections. WA320-6 00-27...
  • Page 40 After inserting the hose in the mating adapter, pull it back to check its connecting condition. (Fig. 5) • When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm (0.14 in). This does not indicate an abnormality. 00-28 WA320-6...
  • Page 41 Hold in the condition in Steps 1 and 2, and pull out whole body (8) to disconnect it. (Fig. 8) Connection Hold the tightening portion and push body (7) in straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9) WA320-6 00-29...
  • Page 42 Hold in the condition in Steps 1 and 2, and pull out whole body (9) to disconnect it. (Fig. 12) Connection Hold the tightening portion and push body (9) in straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13) 00-30 WA320-6...

  • Page 43: Coating Materials

    • Used as sealant for flange surfaces and Gasket bolts at high temperature locations; used to sealant LG-3 790-129-9070 1 kg prevent seizure. • Used as sealant for heat-resistant gasket for high-temperature locations such as engine precombustion chamber, exhaust pipe. WA320-6 00-31...
  • Page 44 • Used for normal temperature, light load G2-CA SYG2-400CA-A Various Various bearing at places in contact with water or Grease SYG2-160CA steam. SYG2-160CNCA 400 g SYG2-400M Belows type • Used for places with heavy load. (10 per case) 00-32 WA320-6...

  • Page 45: Standard Tightening Torque

    1,520 – 1,910 155 – 195 1,121.09 – 1,408.74 1,960 – 2,450 200 – 250 1,445.62 – 1,807.03 2,450 – 3,040 250 – 310 1,807.03 – 2,242.19 2,890 – 3,630 295 – 370 2,131.55 – 2,677.35 ★ Figure A WA320-6 00-33...
  • Page 46 128 – 186 [13.0 – 19.0] {94.41 – 137.19} 157 [16.0] {115.80} type of connector 10, 12 363 – 480 [37.0 – 49.0] {267.73 – 354.03} 422 [43.0] {311.25} 746 – 1010 [76.0 – 103.0] {550.22 – 744.94} 883 [90.0] {651.27} 00-34 WA320-6...
  • Page 47 216 [22.0] {159.31} – – {130.55 – 180.70} 197 – 294 [20.0 – 30.0] (12) 245 [25.0] {180.70} – – {145.30 – 216.84} 246 – 343 [25.0 – 35.0] (14) 294 [30.0] {216.84} – – {181.44 – 252.98} WA320-6 00-35...
  • Page 48 Tightening Torque Thread Size Bolts and Nuts N•m lbf in 10 ±2 1.02 ±0.20 88.51 ±17.70 N•m lbf ft 24 ±4 2.45 ±0.41 17.70 ±2.95 43 ±6 4.38 ±0.61 31.72 ±4.43 77 ±12 7.85 ±1.22 56.79 ±8.85 — — 00-36 WA320-6...
  • Page 49 8 ±2 0.81 ±0.20 70.81 ±17.70 12 ±3 1.22 ±0.20 106.21 ±26.55 N•m lbf ft 15 ±2 1.53 ±0.20 11.06 ±1.48 24 ±4 2.45 ±0.41 17.70 ±2.95 36 ±5 3.67 ±0.51 26.55 ±3.69 60 ±9 6.12 ±0.92 44.25 ±6.64 WA320-6 00-37...

  • Page 50: Conversion Tables

    2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898 00-38 WA320-6...
  • Page 51 This as a preview PDF file from best-manuals.com Download full PDF manual at best-manuals.com...

This manual is also suitable for:

A35001