WHEEL LOADER
SHOP MANUAL
WHEEL LOADER WA320-7 Model
Serial Number
WA320-7
H01051 and up 80001 and up
00 Index and foreword
Emergency steering valve...................................................................................................10-96 Orbitrol valve ..................................................................................................................10-99 Brake system .........................................................................................................................10-105 Layout of brake parts........................................................................................................10-105 Brake accumulator charge valve........................................................................................10-107 Brake valve .....................................................................................................................10-112 Brake accumulator ...........................................................................................................10-116 Slack adjuster.................................................................................................................10-117 Brake .............................................................................................................................10-119 Parking brake control .......................................................................................................10-122 Parking brake ..................................................................................................................10-123 Parking brake solenoid valve ............................................................................................10-124 Undercarriage and frame.........................................................................................................10-126 Axle mount ......................................................................................................................10-126 Center hinge pin ..............................................................................................................10-128 Tire ...........................................................................................................................10-129 Hydraulic system ....................................................................................................................10-131 Hydraulic component layout..............................................................................................10-131 Work equipment control....................................................................................................10-133 Hydraulic tank..................................................................................................................10-134 Double type gear pump ....................................................................................................10-137 Steering and work equipment pump...................................................................................10-138 Control valve ...................................................................................................................10-150 CLSS .............................................................................................................................10-160 Hydraulic circuit diagram and names of valves...................................................................10-164 Self-pressure reducing valve.............................................................................................10-177 Work equipment PPC valve ..............................................................................................10-182 Work equipment lock solenoid valve ..................................................................................10-190 PPC circuit accumulator ...................................................................................................10-191 ECSS accumulator...........................................................................................................10-192 Work equipment .....................................................................................................................10-193 Work equipment linkage ...................................................................................................10-193 Bucket ............................................................................................................................10-194 Cab and its attachments ..........................................................................................................10-195 ROPS cab .......................................................................................................................10-195 Cab mount ......................................................................................................................10-197 Electrical system ....................................................................................................................10-198 Engine control system ......................................................................................................10-198 Preheating system ...........................................................................................................10-201 Engine output limit function ...............................................................................................10-203 Automatic warm-up function..............................................................................................10-204 Parking brake control system ............................................................................................10-205 System operating lamp function.........................................................................................10-209 Battery disconnect switch function .....................................................................................10-210 HST controller system.....................................................................................................10-212 Machine monitor system ..............................................................................................10-252 Rearview monitor system..............................................................................................10-273 KOMTRAX system.....................................................................................................10-276 System component parts ..............................................................................................10-279 Sensor .......................................................................................................................10-302 Central lubrication system (CLS)..........................................................................................................10-323 20 Standard value tables.................................................................................................................... 20-1 Table of contents .................................................................................................................... 20-2 Standard service value table ..................................................................................................20-3 Standard value table for engine ...........................................................................................20-3 Standard value table for machine....................................................................................... 20-5 Standard value table for electrical system....................................................................... 20-17 30 Testing and adjusting.................................................................................................................... 30-1 Table of contents ....................................................................................................................30-2 Related information on testing and adjusting ................................................................................. 30-4
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S-8 Engine lacks power ................................................................................................. 40-948 S-9 KDPF gets clogged in a short time............................................................................. 40-950 S-10 Engine oil consumption is excessive ........................................................................ 40-952 S-11 Engine oil becomes contaminated early.................................................................... 40-953 S-12 Fuel consumption is excessive ................................................................................ 40-954 S-13 Oil is in coolant (or coolant spurts or coolant level goes down)..................................... 40-955 S-14 Oil pressure drops ................................................................................................. 40-956 S-15 Fuel mixes into engine oil........................................................................................40-957 S-16 Water mixes into engine oil (milky) ........................................................................... 40-958 S-17 Coolant temperature rises too high (overheating) ...................................................... 40-959 S-18 Unusual noise is heard ...........................................................................................40-960 S-19 Vibration is excessive .............................................................................................40-961 S-20 Air cannot be bled from fuel circuit ........................................................................... 40-963 S-21 Active regeneration is executed frequently ............................................................... 40-964 S-22 Active regeneration takes time................................................................................. 40-965 S-23 White smoke is exhausted during active regeneration ................................................ 40-966 Central lubrication system (CLS)..................................................................................................... 40-967 50 Disassembly and assembly ....................................................................................................... 50-1 Table of contents .................................................................................................................... 50-2 Related information on disassembly and assembly..................................................................... 50-4 How to read this manual ................................................................................................... 50-4 Coating materials list ........................................................................................................ 50-6 Special tools list ............................................................................................................. 50-10 Sketches of special tools ................................................................................................. 50-15 Engine and cooling system ..................................................................................................... 50-28 Removal and installation of supply pump assembly............................................................. 50-28 Removal and installation of injector assembly..................................................................... 50-31 Removal and installation of cylinder head assembly............................................................ 50-40 Removal and installation of engine hood assembly ............................................................. 50-53 Removal and installation of radiator core assembly ............................................................. 50-55 Removal and installation of aftercooler...............................................................................50-57 Removal and installation of hydraulic oil cooler ................................................................... 50-58 Removal and installation of engine assembly ..................................................................... 50-59 Removal and installation of engine front oil seal.................................................................. 50-67 Removal and installation of engine rear oil seal................................................................... 50-70 Removal and installation of cooling fan and fan motor assembly ........................................... 50-73 Removal and installation of KDPF assembly....................................................................... 50-75 Disassembly and assembly of KDPF assembly .................................................................. 50-78 Removal and installation of KCCV assembly ...................................................................... 50-87 Removal and installation of air cleaner assembly ................................................................ 50-88 Removal and installation of KVGT assembly....................................................................... 50-89 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly....................... 50-92 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly...................... 50-94 Removal and installation of alternator belt .......................................................................... 50-96 Removal and installation of fuel tank assembly ................................................................... 50-97 Power train......................................................................................................................... 50-100 Removal and installation of transfer assembly .................................................................. 50-100 Disassembly and assembly of transfer assembly .............................................................. 50-104 Removal and installation of front axle assembly ................................................................ 50-135 Removal and installation of rear axle assembly................................................................. 50-137 Disassembly and assembly of axle housing assembly....................................................... 50-140 Disassembly and assembly of differential assembly .......................................................... 50-152 Undercarriage and frame...................................................................................................... 50-174 Removal and installation of center hinge pin ..................................................................... 50-174 Removal and installation of counterweight assembly......................................................... 50-183 Hydraulic system .................................................................................................................50-187 Removal and installation of hydraulic tank assembly ......................................................... 50-187 Removal and installation of control valve assembly........................................................... 50-191 Disassembly and assembly of control valve assembly....................................................... 50-195 Removal and installation of hydraulic pump assembly ....................................................... 50-198