SM Wa320-6 70001-Up Sen04162-06

SEN04162-06
WHEEL LOADER WA320 -6
WA320PZ -6
WA320- 70001
SERIAL NUMBERS and up
WA320PZ- 70001
SEN04171-06
WHEEL LOADER 1SHOP MANUAL
WA320-6
WA320PZ-6
Machine model Serial number
WA320-6 70001 and up

WA320PZ-6 70001 and up
00 Index and foreword 00
100 Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
WA320, 320PZ-6 00-100 1

100 Index
SEN04171-06 Composition of shop manual
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs ..................................................................... SEN04162-06
00 Index and foreword .................................................................................................................... SEN04163-06

100 Index .................................................................................................................................. SEN04171-06 q
200 Foreword and general information ..................................................................................... SEN04172-01
01 Specification ............................................................................................................................... SEN04164-01

100 Specification and technical data......................................................................................... SEN04173-01
10 Structure, function and maintenance standard........................................................................... SEN04165-03

100 Engine and cooling system ................................................................................................ SEN04174-01
200 Power train......................................................................................................................... SEN04175-01
300 Steering system ................................................................................................................. SEN04176-01
400 Brake system ..................................................................................................................... SEN04177-00
500 Undercarriage and frame ................................................................................................... SEN04178-00
600 Hydraulic system................................................................................................................ SEN04179-00
700 Work equipment................................................................................................................. SEN04180-02
800 Cab and its attachments .................................................................................................... SEN04181-00
910 Electrical system, Part 1 .................................................................................................... SEN04182-02
920 Electrical system, Part 2 .................................................................................................... SEN04183-03
20 Standard value table................................................................................................................... SEN04166-00

100 Standard service value table.............................................................................................. SEN04184-00
30 Testing and adjusting ................................................................................................................. SEN04167-03

110 Testing and adjusting, Part 1.............................................................................................. SEN04185-02
120 Testing and adjusting, Part 2.............................................................................................. SEN04186-03 q
130 Testing and adjusting, Part 3.............................................................................................. SEN04187-01
40 Troubleshooting.......................................................................................................................... SEN04168-03
100 Failure code table and fuse locations ................................................................................ SEN04188-01
200 General information on troubleshooting............................................................................. SEN04189-02
310 Troubleshooting by failure code (Display of code), Part 1 ................................................. SEN04190-00
00-100 2 WA320, 320PZ-6

100 Index
Composition of shop manual SEN04171-06
350 Troubleshooting by failure code (Display of code), Part 5..................................................SEN04194-01

400 Troubleshooting of electrical system (E-mode) ..................................................................SEN04197-01
500 Troubleshooting of hydraulic and mechanical system (H-mode)........................................SEN04198-01
600 Troubleshooting of engine (S-mode) ..................................................................................SEN04199-01
50 Disassembly and assembly ........................................................................................................SEN04169-03

100 General information on disassembly and assembly...........................................................SEN04200-02
200 Engine and cooling system ................................................................................................SEN04201-03
310 Power train, Part 1..............................................................................................................SEN04202-00
320 Power train, Part 2..............................................................................................................SEN04203-00
400 Undercarriage and frame ...................................................................................................SEN04204-00
500 Hydraulic system ................................................................................................................SEN04205-00
600 Work equipment .................................................................................................................SEN04206-00
700 Cab and its attachments.....................................................................................................SEN04207-00
800 Electrical system ................................................................................................................SEN04208-00
90 Diagrams and drawings ..............................................................................................................SEN04170-03

100 Hydraulic diagrams and drawings ......................................................................................SEN04209-01
200 Electrical diagrams and drawings.......................................................................................SEN04210-03
WA320, 320PZ-6 00-100 3

100 Index
SEN04171-06 Table of contents
Table of contents 1
00 Index and foreword

100 Index SEN04171-06
Composition of shop manual......................................................................................................................... 2
Table of contents ........................................................................................................................................... 4
200 Foreword and general information SEN04172-01
Safety notice ................................................................................................................................................. 2
How to read the shop manual ....................................................................................................................... 7
Explanation of terms for maintenance standard............................................................................................ 9
Handling of electric equipment and hydraulic component............................................................................. 11
Handling of connectors newly used for engines............................................................................................ 20
How to read electric wire code ...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
01 Specification
100 Specification and technical data SEN04173-01
Specification dimension drawing ................................................................................................................... 3
Specifications ................................................................................................................................................ 4
Weight table .................................................................................................................................................. 8
Table of fuel, coolant and lubricants.............................................................................................................. 10
10 Structure, function and maintenance standard

100 Engine and cooling system SEN04174-01
Engine mount and transfer mount................................................................................................................. 2
Damper ......................................................................................................................................................... 3
Cooling system.............................................................................................................................................. 4
Cooling system hydraulic piping diagram...................................................................................................... 5
Cooling fan motor.......................................................................................................................................... 7
200 Power train SEN04175-01
Power train .................................................................................................................................................... 3
Power train system diagram.......................................................................................................................... 4
Drive shaft ..................................................................................................................................................... 6
HST hydraulic piping diagram ....................................................................................................................... 7
HST pump ..................................................................................................................................................... 8
HST motor..................................................................................................................................................... 16
Transfer ......................................................................................................................................................... 22
Clutch solenoid valve .................................................................................................................................... 33
Axle ............................................................................................................................................................... 34
Differential ..................................................................................................................................................... 36
Torque proportioning differential.................................................................................................................... 41
Limited slip differential................................................................................................................................... 44
Final drive...................................................................................................................................................... 48
300 Steering system SEN04176-01
Steering piping diagram ................................................................................................................................ 3
Steering column ............................................................................................................................................ 4
Priority valve.................................................................................................................................................. 5
Orbit-roll valve ............................................................................................................................................... 8
Cushion valve................................................................................................................................................ 16
Steering cylinder............................................................................................................................................ 17
Emergency steering piping diagram.............................................................................................................. 19
Emergency steering valve............................................................................................................................. 20
Steering relief valve....................................................................................................................................... 23
00-100 4 WA320, 320PZ-6

100 Index
Table of contents SEN04171-06
400 Brake system SEN04177-00

Brake piping diagram..................................................................................................................................... 3
Charge valve ................................................................................................................................................. 4
Brake valve.................................................................................................................................................... 8
Inching valve.................................................................................................................................................. 12
Accumulator (for brake) ................................................................................................................................. 13
Slack adjuster ................................................................................................................................................ 14
Brake ............................................................................................................................................................. 16
Parking brake control..................................................................................................................................... 21
Parking brake ................................................................................................................................................ 22
500 Undercarriage and frame SEN04178-00
Axle mount and center hinge pin ................................................................................................................... 2
Tires............................................................................................................................................................... 7
600 Hydraulic system SEN04179-00
Work equipment hydraulic piping diagram .................................................................................................... 2
Work equipment control lever linkage ........................................................................................................... 6
Hydraulic tank................................................................................................................................................ 10
4-gear pump .................................................................................................................................................. 12
Work equipment control valve ....................................................................................................................... 14
Cut-off valve .................................................................................................................................................. 40
PPC valve...................................................................................................................................................... 43
Lock valve...................................................................................................................................................... 58
Accumulator (for PPC circuit) ........................................................................................................................ 59
ECSS valve ................................................................................................................................................... 61
Accumulator (for ECSS) ................................................................................................................................ 63
700 Work equipment SEN04180-02
Work equipment linkage ................................................................................................................................ 2
Bucket............................................................................................................................................................ 6
Bucket positioner and boom kick-out............................................................................................................. 10
Work equipment cylinder ............................................................................................................................... 22
800 Cab and its attachments SEN04181-00
Cab ................................................................................................................................................................ 3
Air conditioner................................................................................................................................................ 4
910 Electrical system, Part 1 SEN04182-02
Machine monitor system................................................................................................................................ 2
Machine monitor ............................................................................................................................................ 6
920 Electrical system, Part 2 SEN04183-03
Electrical system (HST controller system)..................................................................................................... 2
HST controller................................................................................................................................................ 18
ECSS system ................................................................................................................................................ 20
KOMTRAX system ........................................................................................................................................ 22
Engine starting circuit .................................................................................................................................... 24
Engine stopping circuit .................................................................................................................................. 26
Preheating circuit........................................................................................................................................... 27
Engine output derating function..................................................................................................................... 28
Automatic warm-up function .......................................................................................................................... 28
Parking brake circuit ...................................................................................................................................... 30
Coupler plunger control system..................................................................................................................... 32
Max. traction switch ....................................................................................................................................... 33
Multi-function knob ........................................................................................................................................ 34
Sensor ........................................................................................................................................................... 35
20 Standard value table

100 Standard service value table SEN04184-00
Standard service value table for engine ........................................................................................................ 2
Standard service value table for chassis ....................................................................................................... 3
WA320, 320PZ-6 00-100 5

100 Index
30 Testing and adjusting

110 Testing and adjusting, Part 1 SEN04185-02
Tools for testing, adjusting, and troubleshooting ........................................................................................... 3
Measuring engine speed............................................................................................................................... 8
Measuring exhaust gas color ........................................................................................................................ 10
Adjusting valve clearance ............................................................................................................................. 12
Measuring compression pressure ................................................................................................................. 14
Measuring blow-by pressure ......................................................................................................................... 17
Measuring engine oil pressure ...................................................................................................................... 18
Measuring intake air (boost) pressure........................................................................................................... 19
Handling fuel system equipment ................................................................................................................... 21
Releasing residual pressure in fuel system................................................................................................... 21
Measuring fuel pressure................................................................................................................................ 22
Measuring fuel return rate and leakage ........................................................................................................ 24
Bleeding air from fuel circuit.......................................................................................................................... 28
Checking leakage in fuel system................................................................................................................... 29
Handling cylinder cut-out mode operation..................................................................................................... 30
Handling no-injection cranking operation ...................................................................................................... 30
Handling controller voltage circuit ................................................................................................................. 31
Check of muffler and muffler stack for looseness and damage .................................................................... 31
Check of muffler function .............................................................................................................................. 32
Check of installed condition of cylinder head and manifolds......................................................................... 32
Check of engine piping for damage and looseness ...................................................................................... 33
Testing and adjusting air conditioner compressor belt tension...................................................................... 33
Replacing alternator belt ............................................................................................................................... 34
Checking operating force of accelerator pedal.............................................................................................. 3
Checking directional lever ............................................................................................................................. 4
Testing and adjusting HST oil pressure......................................................................................................... 5
Testing clutch control pressure...................................................................................................................... 9
Testing and adjusting steering wheel ............................................................................................................ 10
Testing and adjusting steering oil pressure ................................................................................................... 12
Bleeding air from steering circuit................................................................................................................... 14
Testing hydraulic fan ..................................................................................................................................... 15
Measuring brake pedal.................................................................................................................................. 17
Testing and adjusting brake pedal linkage .................................................................................................... 18
Measuring brake performance ...................................................................................................................... 19
Testing and adjusting accumulator charge pressure..................................................................................... 20
Testing wheel brake oil pressure................................................................................................................... 22
Testing wear of brake disc............................................................................................................................. 25
Bleeding air from wheel brake circuit ............................................................................................................ 26
Releasing residual pressure in brake accumulator circuit............................................................................. 27
Testing parking brake performance............................................................................................................... 28
Testing and adjusting parking brake control cable ........................................................................................ 29
Measuring and adjusting work equipment control lever ................................................................................ 30
Testing and adjusting work equipment hydraulic pressure............................................................................ 31
Testing work equipment PPC oil pressure .................................................................................................... 32
Bleeding air from hydraulic circuit ................................................................................................................. 34
Releasing remaining pressure in hydraulic circuit......................................................................................... 35
Testing and adjusting bucket positioner ........................................................................................................ 36
Testing and adjusting of boom kick-out switch .............................................................................................. 37
Checking proximity switch operation pilot lamp ............................................................................................ 38
Procedure for testing diodes ......................................................................................................................... 39
Preparation work for troubleshooting for electric system .............................................................................. 40
Starting KOMTRAX terminal operations........................................................................................................ 44
Indicator lamps of KOMTRAX terminal ......................................................................................................... 48
00-100 6 WA320, 320PZ-6

100 Index

Adjusting machine monitor ............................................................................................................................ 2
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ............................ 3
Special functions of machine monitor (EMMS).............................................................................................. 5
Pm clinic inspection chart .............................................................................................................................. 58
40 Troubleshooting
100 Failure code table and fuse locations SEN04188-01
Failure codes table ........................................................................................................................................ 2
Fuse locations ............................................................................................................................................... 8
200 General information on troubleshooting SEN04189-02
Points to remember when troubleshooting .................................................................................................... 2
Sequence of events in troubleshooting ......................................................................................................... 3
Testing before troubleshooting ...................................................................................................................... 4
Classification and procedures of troubleshooting.......................................................................................... 5
Information contained in troubleshooting table .............................................................................................. 8
Connection table for connector pin numbers................................................................................................. 10
T- branch box and T- branch adapter table ................................................................................................... 46
310 Troubleshooting by failure code (Display of code), Part 1 SEN04190-00
Failure code [2G40ZG] Brake: Oil pressure reduction .................................................................................. 2
Failure code [6091NX] HST filter: Clogging................................................................................................... 4
Failure code [989FN1] Travel speed: Overrun alarm .................................................................................... 5
Failure code [AA1ANX] Air cleaner: Clogging ............................................................................................... 6
Failure code [AB00L6] Alternator R system: Hot short.................................................................................. 8
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage ................... 10
Failure code [B@BAZG] Engine: Oil pressure reduction............................................................................... 12
Failure code [B@BAZK] Engine oil: Low level............................................................................................... 13
Failure code [B@BCNS] Engine: Overheat................................................................................................... 14
Failure code [B@BCZK] Engine: Low coolant level ...................................................................................... 16
Failure code [B@C6NS] Front brake: High oil temperature .......................................................................... 18
Failure code [B@CRNS] HST: High oil temperature ..................................................................................... 19
Failure code [CA111] Abnormality in engine controller .................................................................................. 3
Failure code [CA115] Engine Ne or Bkup speed sensor error....................................................................... 4
Failure code [CA122] Charge pressure sensor high error............................................................................. 6
Failure code [CA123] Charge pressure sensor low error .............................................................................. 8
Failure code [CA131] Throttle sensor high error ........................................................................................... 10
Failure code [CA132] Throttle sensor low error............................................................................................. 12
Failure code [CA144] Coolant sensor high error ........................................................................................... 14
Failure code [CA145] Coolant sensor low error............................................................................................. 16
Failure code [CA153] Charge temperature sensor high error ....................................................................... 18
Failure code [CA154] Charge temperature sensor low error......................................................................... 20
Failure code [CA155] Derating of speed by abnormally high charge temperature........................................ 22
Failure code [CA187] Sensor power supply 2 low error ................................................................................ 24
Failure code [CA221] Atmospheric pressure sensor high error..................................................................... 26
Failure code [CA222] Atmospheric sensor low error ..................................................................................... 28
Failure code [CA227] Sensor power supply 2 high error............................................................................... 30
Failure code [CA234] Engine overspeed....................................................................................................... 31
Failure code [CA238] Ne speed sensor power supply error.......................................................................... 32
Failure code [CA271] IMV (IMA) Short circuit................................................................................................ 33
Failure code [CA272] IMV (IMA) Disconnection ............................................................................................ 34
Failure code [CA322] Injector #1 open/short error ........................................................................................ 36
WA320, 320PZ-6 00-100 7

100 Index
Failure code [CA342] Calibration code inconsistency................................................................................... 48

Failure code [CA351] Injectors drive circuit error .......................................................................................... 50
Failure code [CA352] Sensor power supply 1 low error................................................................................ 52
Failure code [CA386] Sensor power supply 1 high error .............................................................................. 54
Failure code [CA428] Abnormally high level in water sensor........................................................................ 4
Failure code [CA429] Abnormally low level in water sensor ......................................................................... 6
Failure code [CA431] Idle validation switch error.......................................................................................... 8
Failure code [CA432] Idle validation action error .......................................................................................... 12
Failure code [CA435] Engine oil pressure switch error ................................................................................. 16
Failure code [CA441] Battery voltage low error ............................................................................................ 17
Failure code [CA442] Battery voltage high error ........................................................................................... 20
Failure code [CA449] Common rail pressure high error 2............................................................................. 22
Failure code [CA451] Common rail pressure sensor high error.................................................................... 24
Failure code [CA452] Common rail pressure sensor low error ..................................................................... 26
Failure code [CA488] Derating of torque by abnormally high charge temperature ....................................... 28
Failure code [CA553] Common rail pressure high error 1............................................................................. 29
Failure code [CA559] Supply pump pressure very low error......................................................................... 30
Failure code [CA689] Engine Ne speed sensor error ................................................................................... 32
Failure code [CA731] Engine Bkup speed sensor phase error ..................................................................... 34
Failure code [CA757] All continuous data lost error...................................................................................... 35
Failure code [CA778] Engine Bkup speed sensor error................................................................................ 38
Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 40
Failure code [CA2185] Throttle sensor supply voltage high error ................................................................. 44
Failure code [CA2186] Throttle sensor power supply low error .................................................................... 46
Failure code [CA2249] Supply pump pressure very low error 2.................................................................... 48
Failure code [CA2311] Abnormality in IMV (IMA) solenoid ........................................................................... 50
Failure code [CA2555] Intake heater relay disconnection error .................................................................... 52
Failure code [CA2556] Intake heater relay short circuit error........................................................................ 54
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short ........................................................... 2
Failure code [D192KY] ECSS solenoid relay: Hot short ............................................................................... 4
Failure code [D1B0KA] HST safety relay: Disconnection ............................................................................. 6
Failure code [D1B0KB] HST safety relay: Ground fault ................................................................................ 8
Failure code [D1B0KY] HST safety relay: Hot short ..................................................................................... 10
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ............................................................. 12
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection.................................................. 14
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection ................................................ 16
Failure code [DAJ0KK] HST controller power supply: Low voltage .............................................................. 20
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality .................................................... 22
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault ................................... 24
Failure code [DAJ1L6] HST controller main power line: Hot short................................................................ 26
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage ....................................................... 28
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness............. 30
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault ............ 32
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range......................................................... 34
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals............. 36
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection ..................................................... 37
Failure code [DAJRMA] HST controller: Disagreement in option selection .................................................. 43
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line....................................... 2
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality .................................................. 8
Failure code [DD1NLD] Fan reverse switch signal: Abnormality .................................................................. 10
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short ........................................ 12
Failure code [DDB6KB] Parking brake indicator signal: Ground fault ........................................................... 14
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking brake reminder switch
(intermediate switch): Trouble................................................................................................................. 16
Failure code [DDB6L0] Parking brake reminder signal: Ground fault ........................................................... 18
00-100 8 WA320, 320PZ-6

100 Index
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short.......................................... 20

Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault ................................. 22
Failure code [DDD7KY] Travel speed control dial signal: Hot short .............................................................. 24
Failure code [DDE5MA] Emergency steering operation switch: Disconnection ............................................ 26
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault................................................................... 28
Failure code [DDK6KY] FNR lever: Hot short................................................................................................ 32
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) ................................ 34
Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault ............................ 2
Failure code [DF10KB] Travel speed range selector switch: Hot short ......................................................... 6
Failure code [DGH1KX] HST oil temperature sensor: Ground fault .............................................................. 8
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault ............................................................ 9
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short.......................................... 10
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault ............................................ 12
Failure code [DHH1KY] HST oil pressure sensor: Hot short ......................................................................... 14
Failure code [DHTCL6] HST filter clogging sensor: Functional defect .......................................................... 16
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short .............................................................. 18
Failure code [DLT3KX] Travel speed sensor B: Abnormality......................................................................... 20
Failure code [DLT4KX] Travel speed sensor A: Abnormality......................................................................... 24
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality .................................................................. 26
Failure code [DV00KY] Alarm buzzer: Hot short ........................................................................................... 28
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault ........................................................ 30
Failure code [DW26KY] Motor 2 solenoid: Hot short..................................................................................... 32
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short ................................................................... 34
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault ...................................... 36
Failure code [DX16KA] Fan EPC solenoid: Disconnection ........................................................................... 2
Failure code [DX16KB] Fan EPC solenoid: Ground fault .............................................................................. 3
Failure code [DX16KY] Fan EPC solenoid: Hot short ................................................................................... 4
Failure code [DX19KA] Motor 1 solenoid: Disconnection.............................................................................. 6
Failure code [DX19KB] Motor 1 solenoid: Ground fault................................................................................. 8
Failure code [DX19KY] Motor 1 solenoid: Hot short...................................................................................... 10
Failure code [DX20KA] Clutch EPC solenoid: Disconnection ....................................................................... 12
Failure code [DX20KB] Clutch EPC solenoid: Ground fault .......................................................................... 14
Failure code [DX20KY] Clutch EPC solenoid: Hot short ............................................................................... 16
Failure code [DXH7KB] Reverse solenoid: Ground fault............................................................................... 18
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short............................................................. 20
Failure code [DXH8KB] Forward solenoid: Ground fault ............................................................................... 22
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short............................................................. 24
Failure code [J141N1] Steering pump: Overrun alarm .................................................................................. 26
Failure code [M100N1] HST pump: Overrun alarm ....................................................................................... 26
Failure code [M400N1] Motor 1: Overrun alarm ............................................................................................ 27
400 Troubleshooting of electrical system (E-mode) SEN04197-01
E-1 Engine does not start .............................................................................................................................. 3
E-2 Preheater does not operate normally...................................................................................................... 10
E-3 Travel speed is low or high ..................................................................................................................... 14
E-4 ECSS does not operate .......................................................................................................................... 20
E-5 ECSS keeps operating............................................................................................................................ 23
E-6 Defective boom kick-out function and cancellation ................................................................................. 26
E-7 Defective bucket positioner function and cancellation ............................................................................ 30
E-8 Defective lift arm FLOATING holding function and cancellation ............................................................. 34
E-9 Travel direction selection system does not function................................................................................ 38
E-10 Fan does not reverse ............................................................................................................................ 42
E-11 Fan keeps rotating in reverse................................................................................................................ 46
E-12 Wiper does not operate......................................................................................................................... 48
E-13 Windshield washer does not operate.................................................................................................... 52
E-14 Headlamp, clearance lamp and tail lamp do not light up or go off ........................................................ 56
E-15 Working lamp does not light up or go off............................................................................................... 64
WA320, 320PZ-6 00-100 9

100 Index
E-16 Turn signal lamp and hazard lamp do not light up or go off.................................................................. 70
E-17 Brake lamp does not light or it keeps lighting up .................................................................................. 76
E-18 Backup lamp does not light or it keeps lighting up ............................................................................... 78
E-19 Backup alarm does not sound or it keeps sounding............................................................................. 81
E-20 Horn does not sound or it keeps sounding ........................................................................................... 84
E-21 Alarm buzzer does not sound or it keeps sounding.............................................................................. 86
E-22 Air conditioner does not operate or stop............................................................................................... 88
E-23 The KOMTRAX system does not work properly................................................................................... 92
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN04198-01
Method of using troubleshooting chart .......................................................................................................... 3
Failure code and cause table ........................................................................................................................ 6
H-1 The machine does not start.................................................................................................................... 8
H-2 The travel speed is slow......................................................................................................................... 9
H-3 The traction force is weak ...................................................................................................................... 10
H-4 Engine stalls when traveling or engine speed drops excessively........................................................... 11
H-5 Shift range is not shifted ......................................................................................................................... 12
H-6 The steering wheel does not turn ........................................................................................................... 13
H-7 The steering wheel is heavy................................................................................................................... 14
H-8 Steering wheel shakes or jerks............................................................................................................... 15
H-9 Machine deviates naturally to one side when traveling .......................................................................... 15
H-10 The brake does not work or does not work well ................................................................................... 16
H-11 The brake is not released or is dragged ............................................................................................... 17
H-12 The lift arm does not rise or lower ........................................................................................................ 18
H-13 The lift arm moves slowly or the lift arm rising force is insufficient ....................................................... 19
H-14 When rising, the lift arm comes to move slowly at specific height........................................................ 20
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air)................................... 20
H-16 Hydraulic drifts of the lift arm occur often ............................................................................................. 20
H-17 The lift arm wobbles during operation .................................................................................................. 20
H-18 When the control lever is switched from HOLD to RAISE, the lift arm falls temporarily .................. 21
H-19 The bucket does not tilt back................................................................................................................ 22
H-20 The bucket moves slowly or the tilting-back force is insufficient .......................................................... 23
H-21 The bucket comes to operate slowly in the midst of tilting-back .......................................................... 24
H-22 The bucket cylinder cannot hold down the bucket ............................................................................... 24
H-23 Hydraulic drifts of the bucket occur often ............................................................................................. 24
H-24 The bucket wobbles during travel with load (The work equipment valve is set to HOLD) ................. 24
H-25 When the control lever is switched from HOLD to TILT, the bucket falls temporarily ...................... 25
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy................................... 25
H-27 The ECSS does not operate and machine pitches and bounces......................................................... 26
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) ................ 27
600 Troubleshooting of engine (S-mode) SEN04199-01
Method of using troubleshooting charts ........................................................................................................ 2
S-1 Starting performance is poor .................................................................................................................. 6
S-2 Engine does not start.............................................................................................................................. 8
S-3 Engine does not pick up smoothly.......................................................................................................... 11
S-4 Engine stops during operations .............................................................................................................. 12
S-5 Engine does not rotate smoothly ............................................................................................................ 13
S-6 Engine lacks output (or lacks power)...................................................................................................... 14
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 16
S-9 Oil becomes contaminated quickly ......................................................................................................... 17
S-10 Fuel consumption is excessive............................................................................................................. 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 19
S-12 Oil pressure drops ................................................................................................................................ 20
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 21
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 22
S-15 Abnormal noise is made ....................................................................................................................... 23
S-16 Vibration is excessive ........................................................................................................................... 24
00-100 10 WA320, 320PZ-6

100 Index
50 Disassembly and assembly

100 General information on disassembly and assembly SEN04200-02
Coating materials list ..................................................................................................................................... 4
Coating materials list ..................................................................................................................................... 4
Special tool list............................................................................................................................................... 7
Sketches of special tools ............................................................................................................................... 11
200 Engine and cooling system SEN04201-03
Removal and installation of fuel supply pump assembly ............................................................................... 2
Removal and installation of fuel injector assembly ........................................................................................ 5
Removal and installation of cylinder head assembly..................................................................................... 13
Removal and installation of engine hood assembly ...................................................................................... 25
Removal and installation of radiator .............................................................................................................. 28
Removal and installation of air aftercooler..................................................................................................... 31
Removal and installation of hydraulic oil cooler assembly ............................................................................ 33
Removal and installation of engine assembly ............................................................................................... 35
Removal and installation of engine front oil seal assembly ........................................................................... 41
Removal and installation of engine rear oil seal assembly............................................................................ 44
Removal and installation of cooling fan and fan motor assembly.................................................................. 47
Removal and installation of fuel tank assembly............................................................................................. 50
310 Power train, Part 1 SEN04202-00
Removal and installation of transfer assembly .............................................................................................. 2
Disassembly and assembly of transfer assembly.......................................................................................... 5
Removal and installation of parking brake assembly..................................................................................... 24
Disassembly and assembly of parking brake assembly ................................................................................ 25
320 Power train, Part 2 SEN04203-00
Removal and installation of front axle assembly ........................................................................................... 2
Removal and installation of rear axle assembly ............................................................................................ 4
Disassembly and assembly of axle housing assembly.................................................................................. 7
Disassembly and assembly of differential assembly ..................................................................................... 19
400 Undercarriage and frame SEN04204-00
Removal and installation of center hinge pin................................................................................................. 2
Removal and installation of counterweight assembly.................................................................................... 12
500 Hydraulic system SEN04205-00
Removal and installation of HST pump and 4-gear pump assembly............................................................. 2
Disassembly and assembly of HST pump assembly..................................................................................... 5
Removal and installation of HST motor 1 assembly ...................................................................................... 32
Removal and installation of HST motor 2 assembly ...................................................................................... 34
Disassembly and assembly of HST motor assembly .................................................................................... 36
Removal and installation of work equipment control valve assembly............................................................ 52
Removal and installation of hydraulic tank assembly .................................................................................... 54
Disassembly and assembly of hydraulic cylinder assembly .......................................................................... 56
600 Work equipment SEN04206-00
Removal and installation of work equipment assembly................................................................................. 2
700 Cab and its attachments SEN04207-00
Removal and installation of operator's cab and floor frame assembly .......................................................... 2
Removal and installation of operator's cab glass (Stuck glass)..................................................................... 8
Disassembly and assembly of operator's seat assembly .............................................................................. 16
Removal and installation of air conditioner unit ............................................................................................. 26
800 Electrical system SEN04208-00
Removal and installation of monitor panel..................................................................................................... 2
Removal and installation of engine controller assembly................................................................................ 4
Removal and installation of HST controller assembly ................................................................................... 5
Removal and installation of KOMTRAX terminal assembly........................................................................... 6
WA320, 320PZ-6 00-100 11

100 Index
90 Diagrams and drawings

100 Hydraulic diagrams and drawings SEN04209-01
Automatic greasing circuit diagram ............................................................................................................... 2
Hydraulic circuit diagram............................................................................................................................... 5
200 Electrical diagrams and drawings SEN04210-03
Electrical circuit diagram ............................................................................................................................... 3
Connector list and stereogram ...................................................................................................................... 29
00-100 12 WA320, 320PZ-6

100 Index
WA320, 320PZ-6 00-100 13

SEN04171-06
WA320-6, WA320PZ-6 Wheel loader

Form No. SEN04171-06
2011 KOMATSU
All Rights Reserved
Printed in Japan 01-11
00-100 14
SEN04172-01
WA320-6
WA320PZ-6
WA320-6 70001 and up

00 Index and foreword 00
200 Foreword and general information

Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
WA320, 320PZ-6 00-200 1

SEN04172-01 Safety notice
Safety notice (Rev. 2008/08)1

Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs in the operator's compartment.
5) Only qualified workers must carry out work
and operation which require license or
qualification.
6) Keep all tools in good condition, learn the
correct way to use them, and use the
proper ones of them. Before starting work,
thoroughly check the tools, machine, fork-
lift, service car, etc.
00-200 2 WA320, 320PZ-6

Safety notice SEN04172-01
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative () terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
places. Operate the hoist or crane slowly
to prevent the component from hitting any
other part. Do not work with any part still
raised by the hoist or crane.
WA320, 320PZ-6 00-200 3

4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker must always stand in front of the
load and guide the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling
work.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60, as a rule.
Do not sling a heavy load with ropes form-
ing a wide hanging angle from the hook.
When hoisting a load with 2 or more
ropes, the force subjected to each rope
will increase with the hanging angle. The
table below shows the variation of allow-
able load in kN {kg} when hoisting is made
with 2 ropes, each of which is allowed to
sling up to 9.8 kN {1,000 kg} vertically, at
various hanging angles. When the 2 ropes 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
00-200 4 WA320, 320PZ-6

Safety notice SEN04172-01
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard Z twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
WA320, 320PZ-6 00-200 5

8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
a Never release the refrigerant (R134a)
to the atmosphere.
k If the refrigerant gas gets in your
eyes or contacts your skin, you
may lose your sight and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
00-200 6 WA320, 320PZ-6

How to read the shop manual SEN04172-01
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the Chassis volume and Engine volume. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
20. Standard value table

This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting

This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The S mode of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly

This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
WA320, 320PZ-6 00-200 7

SEN04172-01 How to read the shop manual
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 )
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
00-200 8 WA320, 320PZ-6

Explanation of terms for maintenance standard SEN04172-01
Explanation of terms for maintenance standard 1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the
machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance

q To be accurate, the finishing size of parts
is a little different from one to another.
q To specify a finishing size of a part, a tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the standard size and the range of differ-
ence from the standard size is called the
tolerance.
q The tolerance with the symbols of + or is
indicated on the right side of the standard
size.
Example:
Standard size Tolerance
0.022
120
0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
0.030 +0.046
60
0.076 +0
WA320, 320PZ-6 00-200 9

SEN04172-01 Explanation of terms for maintenance standard
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the standard clear- between them is increased to a certain
ance, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the clearance limit.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
standard value, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value interference limit.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance table is smaller than that of the
mating shaft, the difference between those
diameters is called the interference.
q The range (A B) from the difference (A)
between the minimum size of the shaft
and the maximum size of the hole to the
difference (B) between the maximum size
of the shaft and the minimum size of the
hole is the standard interference.
q After repairing or replacing some parts,
measure the size of their hole and shaft
and check that the interference is in the
standard range.
4. Repair limit and allowable value or allow-

able dimension
q The size of a part changes because of
wear and deformation while it is used. The
limit of changed size is called the repair
limit.
q If a part is worn to the repair limit, it must
be replaced or repaired.
q The performance and function of a prod-
uct lowers while it is used. A value which
the product can be used without causing a
problem is called the allowable value or
allowable dimension.
q If a product is worn to the allowable value,
it must be checked or repaired. Since the
permissible value is estimated from vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
00-200 10 WA320, 320PZ-6

Handling of electric equipment and hydraulic component SEN04172-01
Handling of electric equipment and hydraulic component 1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles
before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must
be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on Handling electric equipment and
Handling hydraulic equipment (particularly gear oil and hydraulic oil).
Points to remember when handling electric

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are frequently removed and installed again, so
they are likely to suffer deformation or damage.
For this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness

1) Defective contact of connectors (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
WA320, 320PZ-6 00-200 11

SEN04172-01 Handling of electric equipment and hydraulic component
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), but if high-pressure water is sprayed
directly on the connector, water may enter
the connector, depending on the direction
of the water jet. Accordingly, take care not
to splash water over the connector. The
connector is designed to prevent water
from entering, but at the same time, if
water does enter, it is difficult for it to be
drained. Therefore, if water should get into
the connector, the pins will be short-cir-
cuited by the water, so if any water gets in,
immediately dry the connector or take
other appropriate action before passing
electricity through it.
5) Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
00-200 12 WA320, 320PZ-6

3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
When disconnecting the connectors,
hold the connectors. For connectors
held by a screw, loosen the screw
fully, then hold the male and female
connectors in each hand and pull
apart. For connectors which have a
lock stopper, press down the stopper
with your thumb and pull the connec-
tors apart.
a Never pull with one hand.
2] When removing from clips

q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is
installed.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
After removing any connector, cover it
with a vinyl bag to prevent any dust,
dirt, oil, or water from getting in the
connector portion.
a If the machine is left disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
WA320, 320PZ-6 00-200 13

2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
a If there is any oil, water, or dirt
stuck to the connector, wipe it off
with a dry cloth. If any water has
got inside the connector, warm
the inside of the wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected easily, remove the clamp
and adjust the position.
q If the connector clamp has been
removed, be sure to return it to
its original position. Check also
that there are no loose clamps.
00-200 14 WA320, 320PZ-6

3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally until the lock clicks.
Arrow: 1)
2] Since locks (a) and (b) may not be set
completely, push in female connector
(2) while moving it up and down until
the locks are set normally.
Arrow: 1), 2), 3)
a Right of figure: Lock (a) is pulled
down (not set completely) and
lock (b) is set completely.
(1): Male connector
(2): Female connector
(a), (b): Locks
WA320, 320PZ-6 00-200 15

4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the
connector must be washed in water, do
not use high-pressure water or steam
directly on the wiring harness. If water
gets directly on the connector, do as fol-
lows.
1] Disconnect the connector and wipe
off the water with a dry cloth.
a If the connector is blown dry with
compressed air, there is the risk
that oil in the air may cause
defective contact, so remove all
oi l a nd wa ter fr om t he c om -
pressed air before blowing with
air.
2] Dry the inside of the connector with a
dryer.
If water gets inside the connector, use
a dryer to dry the connector.
a Hot air from the dryer can be
used, but regulate the time that
the hot air is used in order not to
make the connector or related
parts too hot, as this will cause
deformation or damage to the
connector.
3] Carry out a continuity test on the con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
00-200 16 WA320, 320PZ-6

4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol all of the electronic circuits on the
machine, so be extremely careful when
handling the controller.
2) Do not place objects on top of the control-
ler.
3) Cover the control connectors with tape or
a vinyl bag. Never touch the connector
contacts with your hand.
4) During rainy weather, do not leave the
controller in a place where it is exposed to
rain.
5) Do not place the controller on oil, water, or
soil, or in any hot place, even for a short
time. (Place it on a suitable dry stand).
6) Precautions when carrying out arc welding
When carrying out arc welding on the
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
WA320, 320PZ-6 00-200 17

Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during

refilling operations
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
00-200 18 WA320, 320PZ-6

5. Change hydraulic oil when the temperature

is high
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as
possible of the old hydraulic oil must be
drained out. (Drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) 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.
6. Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
WA320, 320PZ-6 00-200 19

SEN04172-01 Handling of connectors newly used for engines
Handling of connectors newly used for engines 1
a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 170, 12V140 engines tor (2) outward.
q Various pressure sensors and NE
speed sensor
Examples)
Intake air pressure sensor in intake
manifold: PIM
(125, 170, 12V140 engines)
Oil pressure sensor: POIL
(125, 170, 12V140 engines)
Oil pressure switch
(95, 107, 114 engines)
Ne speed sensor of flywheel housing:
NE (95 170, 12V140 engines)
Ambient pressure sensor: PAMB
(125, 170, 12V140 engines)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
00-200 20 WA320, 320PZ-6

Handling of connectors newly used for engines SEN04172-01
3. Push lock type

q 95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the fol-

lowing procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q 114 engine
q 107, 114 engines

Example)
Intake air pressure/temperature sensor in
intake manifold
(SUMITOMO-04)
3) While pressing lock (D), pull out connector

(4) in the direction of the arrow.
q 107 engine
a If the lock is on the underside, use

flat-head screwdriver [1] since you
cannot insert your fingers.
2) While pressing up lock (C) of the connec-
tor with flat-head screwdriver [1], pull out
connector (3) in the direction of the arrow.
WA320, 320PZ-6 00-200 21

SEN04172-01 Handling of connectors newly used for engines
q 95, 125 170, 12V140 engines 4. Turn-housing type (Round green connector)
4) While pressing lock (E) of the connector, q 140 engine
pull out connector (5) in the direction of Example)
the arrow. Intake air pressure sensor in intake mani-
fold (CANNON-04): PIM etc.
Example)
Fuel pressure sensor in common rail: 1) Disconnect connector (6) according to the
PFUEL etc. (AMP-3) following procedure.
1] Turn housing (H1) in the direction of
the arrow.
a When connector is unlocked,
housing (H1) becomes heavy to
turn.
2] Pull out housing (H1) in the direction
of the arrow.
a Housing (H1) is left on the wiring har-
ness side.
Example)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
2) Connect the connector according to the

following procedure.
1] Insert the connector to the end, while
setting its groove.
2] Turn housing (H1) in the direction of
the arrow until it clicks.
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
00-200 22 WA320, 320PZ-6

How to read electric wire code SEN04172-01
How to read electric wire code 1
a The information about the wires unique to each machine model is described in Troubleshooting section,
Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by sym-
bols. The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX 0.85 L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nomi-
nal No. of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.

Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.

Type, symbol, and material of wire are shown in Table 1.
(Since AV and AVS are classified by size (nominal No.), they are not indi-
cated.)
1. Type, symbol, and material

AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in
thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1)
Using
Sym-
Type Material temperature Example of use
bol
range (C)
Low-voltage Conduc- Annealed copper for elec-
tor tric appliance General wiring
wire for AV
(Nominal No. 5 and above)
automobile Insulator Soft polyvinyl chloride
Thin-cover Conduc- Annealed copper for elec- 30 to +60
low-voltage tor tric appliance General wiring
AVS
wire for (Nominal No. 3 and below)
Insulator Soft polyvinyl chloride
automobile
Heat-resis- Conduc- Annealed copper for elec-
tor tric appliance General wiring in extremely
tant low-volt-
AEX 50 to +110 cold district, wiring at high-tem-
age wire for Heat-resistant crosslinked
Insulator perature place
automobile polyethylene
WA320, 320PZ-6 00-200 23

SEN04172-01 How to read electric wire code
2. Dimensions
(Table 2)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
eter of strand
Conductor
Sectional
0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
area (mm2)
d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6
Cov-
AV Standard 4.6
er D
AEX Standard 2.0 2.2 2.7 3.0 3.1 3.8 4.6
Nominal No. 8 15 20 30 40 50 60 85 100

Number of
strands/Diam- 50/0.45 84/0.45 41/0.80 70/0.80 85/0.80 108/0.80 127/0.80 169/0.80 217/0.80
eter of strand
Conductor
Sectional
7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
area (mm2)
d (approx.) 3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
AVS Standard
Cov-
AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
er D
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
f of nominal No. denotes flexible.
00-200 24 WA320, 320PZ-6

How to read electric wire code SEN04172-01
3. Color codes table
(Table 3)
Color Code Color of wire Color Code Color of wire
B Black LgW Light green & White
Br Brown LgY Light green & Yellow
BrB Brown & Black LR Blue & Red
BrR Brown & Red LW Blue & White
BrW Brown & White LY Blue & Yellow
BrY Brown & Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red & Black
GB Green & Black RG Red & Green
GL Green & Blue RL Red & Blue
Gr Gray RW Red & White
GR Green & Red RY Red & Yellow
GW Green & White Sb Sky Blue
GY Green & Yellow Y Yellow
L Blue YB Yellow & Black
LB Blue & Black YG Yellow &Green
Lg Light green YL Yellow & Blue
LgB Light green & Black YR Yellow & Red
LgR Light green & Red YW Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and
the second color is the color of the marking.
Example: GW means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire AVS or AV AEX
Charge R WG R
Ground B B
Start R R
Light RW RB RY RG RL D
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB L
Type of
Br BrW BrR BrY BrB
circuit
Lg LgR LgY LgB LgW
O
Others Gr
P
Sb
Dg
Ch
WA320, 320PZ-6 00-200 25

SEN04172-01 Precautions when carrying out operation
Precautions when carrying out operation 1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work

q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when dis-
connecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising components, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
Plug (nut end) Sleeve nut (elbow end)
number
02 07376-70210 02789-20210
03 07376-70315 02789-20315
04 07376-70422 02789-20422
05 07376-70522 02789-20522
06 07376-70628 02789-20628
10 07376-71034 07221-21034
12 07376-71234 07221-21234
2) Split flange type hoses and tubes

Nominal
Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-30400
05 07379-00500 07378-10500 07371-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part Number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
00-200 26 WA320, 320PZ-6

Precautions when carrying out operation SEN04172-01
2. Precautions when carrying out installation work

q Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded por-
tion with 2 3 drops of adhesive.
q When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with gasket sealant.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with anti-friction compound (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, always bleed the air as follows:
1) Start the engine and run at low idle.
2) Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder 100 mm from the end of its stroke.
3) Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4) After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation

1) Refilling with coolant, oil and grease
q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level.
Run the engine to circulate the coolant through the system. Then check the coolant level
again.
q If the hydraulic equipment has been removed and installed again, add engine oil to the speci-
fied level. Run the engine to circulate the oil through the system. Then check the oil level
again.
q If the piping or hydraulic equipment have been removed, always bleed the air from the system
after reassembling the parts.
a For details, see Testing and adjusting, Bleeding air.
q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment
parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see Disassembly and assembly.
3) Checking engine piping for damage and looseness
Intake and exhaust system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air
suction and exhaust gas leakage.
If any part is loosened or damaged, retighten or repair it.
Cooling system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for
coolant leakage.
Fuel system
Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel
leakage.
WA320, 320PZ-6 00-200 27

SEN04172-01 Precautions when carrying out operation
4) Checking muffler and exhaust pipe for damage and looseness

1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage.
If any part is damaged, replace it.
2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for
looseness.
If any bolt or nut is loosened, retighten it.
5) 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, referring to Troubleshooting and Disassembly
and assembly.
00-200 28 WA320, 320PZ-6

Method of disassembling and connecting push-pull type coupler SEN04172-01
Method of disassembling and connecting push-pull type coupler 1
k Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to
release the residual pressure from the hydraulic tank.
k Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1
1. Disconnection
1) Hold adapter (1) and push hose joint (2)
into mating adapter (3). (Fig. 1)
a The adapter can be pushed in about
3.5 mm.
a Do not hold rubber cap portion (4).
2) After hose joint (2) is pushed into adapter
(3), press rubber cap portion (4) against
adapter (3) until it clicks. (Fig. 2)
3) Hold hose adapter (1) or hose (5) and pull
it out. (Fig. 3)
a Since some hydraulic oil flows out,
prepare an oil receiving container.
2. Connection
1) Hold hose adapter (1) or hose (5) and
insert it in mating adapter (3), aligning
them with each other. (Fig. 4)
a Do not hold rubber cap portion (4).
2) After inserting the hose in the mating
adapter perfectly, pull it back to check its
connecting condition. (Fig. 5)
a When the hose is pulled back, the
rubber cap portion moves toward the
hose about 3.5 mm. This does not
indicate abnormality, however.
WA320, 320PZ-6 00-200 29

SEN04172-01 Method of disassembling and connecting push-pull type coupler
Type 2
1. Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexag-
onal portion at the male end. (Fig. 6)
2) While holding the condition of Step 1), turn
lever (8) to the right (clockwise). (Fig. 7)
3) While holding the condition of Steps 1)
and 2), pull out whole body (7) to discon-
nect it. (Fig. 8)
2. Connection
q Hold the tightening portion and push body
contacts contact surface (a) of the hexag-
00-200 30 WA320, 320PZ-6

Method of disassembling and connecting push-pull type coupler SEN04172-01
Type 3
1. Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexag-
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal por-
tion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to discon-
nect it. (Fig. 12)
2. Connection
q Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexag-
WA320, 320PZ-6 00-200 31

SEN04172-01 Standard tightening torque table
Standard tightening torque table 1
1. Table of tightening torques for bolts and nuts

a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of bolt Width across flats Tightening torque

mm mm Nm kgm
6 10 11.8 14.7 1.2 1.5
8 13 27 34 2.8 3.5
10 17 59 74 6.0 7.5
12 19 98 123 10.0 12.5
14 22 157 196 16 20
16 24 245 309 25 31.5
18 27 343 427 35 43.5
20 30 490 608 50 62
22 32 662 829 67.5 84.5
24 36 824 1,030 84 105
27 41 1,180 1,470 120 150
30 46 1,520 1,910 155 195
33 50 1,960 2,450 200 250
36 55 2,450 3,040 250 310
39 60 2,890 3,630 295 370
a The following table applies to the bolts in Fig. B.

mm mm Nm kgm
6 10 5.9 9.8 0.6 1.0
8 13 13.7 23.5 1.4 2.4
10 14 34.3 46.1 3.5 4.7
12 27 74.5 90.2 7.6 9.2
a Fig. A a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are
the ones indicated in the table for bolts shown in Fig. B.
(Values of tightening torques shown in the table for Fig. A are applied.)
00-200 32 WA320, 320PZ-6

Standard tightening torque table SEN04172-01
2. Table of tightening torques for split flange bolts

a Unless there are special instructions, tighten split flange bolts to the torque below.

mm mm Nm kgm
10 14 59 74 6.0 7.5
12 17 98 123 10.0 12.5
16 22 235 285 23.5 29.5
3. Table of tightening torques for O-ring boss piping joints

a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Thread diameter Width across flats Tightening torque Nm {kgm}

Nominal No.
mm mm Range Target
02 14 35 63 { 3.5 6.5} 44 { 4.5}
03,04 20 Varies depending 84 132 { 8.5 13.5} 103 {10.5}
05,06 24 on type of connec- 128 186 {13.0 19.0} 157 {16.0}
10,12 33 tor. 363 480 {37.0 49.0} 422 {43.0}
14 42 746 1,010 {76.0 103} 883 {90.0}
4. Table of tightening torques for O-ring boss plugs

a Unless there are special instructions, tighten O-ring boss plugs to the torque below.
Nominal Thread diameter Width across flats Tightening torque Nm {kgm}

No. mm mm Range Target
08 8 14 5.88 8.82 {0.6 0.9} 7.35 {0.75}
10 10 17 9.81 12.74 {1.0 1.3} 11.27 {1.15}
12 12 19 14.7 19.6 {1.5 2.0} 17.64 {1.8}
14 14 22 19.6 24.5 {2.0 2.5} 22.54 {2.3}
16 16 24 24.5 34.3 {2.5 3.5} 29.4 {3.0}
18 18 27 34.3 44.1 {3.5 4.5} 39.2 {4.0}
20 20 30 44.1 53.9 {4.5 5.5} 49.0 {5.0}
24 24 32 58.8 78.4 {6.0 8.0} 68.6 {7.0}
30 30 32 93.1 122.5 { 9.5 12.5} 107.8 {11.0}
33 33 107.8 147.0 {11.0 15.0} 127.4 {13.0}
36 36 36 127.4 176.4 {13.0 18.0} 151.9 {15.5}
42 42 181.3 240.1 {18.5 24.5} 210.7 {21.5}
52 52 274.4 367.5 {28.0 37.5} 323.4 {33.0}
WA320, 320PZ-6 00-200 33

SEN04172-01 Standard tightening torque table
5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm} Taper seal Face seal

Nominal Width Nominal No.
No. of across Thread
Thread size Number of
hose flats Range Target diameter (mm)
(mm) threads, type of
(Reference)
thread
34 54 { 3.5 5.5} 9/16-18UN 14.3
02 19 44 { 4.5}
34 63 { 3.5 6.5} 14
22 54 93 { 5.5 9.5} 74 { 7.5} 11/16-16UN 17.5
03
24 59 98 { 6.0 10.0} 78 { 8.0} 18
04 27 84 132 { 8.5 13.5} 103 {10.5} 22 13/16-16UN 20.6
05 32 128 186 {13.0 19.0} 157 {16.0} 24 1-14UNS 25.4
06 36 177 245 {18.0 25.0} 216 {22.0} 30 1-3/16-12UN 30.2
(10) 41 177 245 {18.0 25.0} 216 {22.0} 33
(12) 46 197 294 {20.0 30.0} 245 {25.0} 36
(14) 55 246 343 {25.0 35.0} 294 {30.0} 42
6. Table of tightening torques for face seal joints

a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to
be used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer Width Tightening torque Nm {kgm} Face seal

diameter across Nominal No. Thread diameter
of pipe flats Range Target Number of threads, (mm)
(mm) (mm) type of thread (Reference)
8 19 14 16 {1.4 1.6} 15 {1.5} 9/16-18UN 14.3
10 22 24 27 {2.4 2.7} 25.5 {2.6} 11/16-16UN 17.5
12 24 (27) 43 47 {4.4 4.8} 45 {4.6} 13/16-16UN 20.6
15 (16) 30 (32) 60 68 {6.1 6.8} 64 {6.5} 1-14UN 25.4
22 (20) 36 90 95 {9.2 9.7} 92.5 {9.4} 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Thread size
Bolts and nuts
mm Nm kgm
6 10 2 1.02 0.20
8 24 4 2.45 0.41
10 43 6 4.38 0.61
12 77 12 7.85 1.22
14
00-200 34 WA320, 320PZ-6

Standard tightening torque table SEN04172-01
8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine
series to the torque below.
Thread size Tightening torque

mm Nm kgm
6 82 0.81 0.20
8 10 2 1.02 0.20
10 12 2 1.22 0.20
12 24 4 2.45 0.41
14 36 5 3.67 0.51
9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114
engine series to the torque below.
Tightening torque
Material In cast iron or steel In aluminum
Thread size (inch) Nm kgm Nm kgm
1/16 15 2 1.53 0.20 51 0.51 0.10
1/8 20 2 2.04 0.20 15 2 1.53 0.20
1/4 25 3 2.55 0.31 20 2 2.04 0.20
3/8 35 4 3.57 0.41 25 3 2.55 0.31
1/2 55 6 5.61 0.61 35 4 3.57 0.41
3/4 75 8 7.65 0.82 45 5 4.59 0.51
WA320, 320PZ-6 00-200 35

SEN04172-01 Conversion table
Conversion table 1
Method of using the conversion table

The conversion table in this section is provided to enable simple conversion of figures. For details of the
method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.

1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a hori-
zontal line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches (B)

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-200 36 WA320, 320PZ-6

Conversion table SEN04172-01
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
Liters to U.S. Gallons

1 l = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
WA320, 320PZ-6 00-200 37

Liters to U.K. Gallons

1 l = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
kgm to ft.lb
1 kgm = 7.233 ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-200 38 WA320, 320PZ-6

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1,010 1,024 1,038 1,053 1,067 1,081 1,095 1,109 1,124
80 1,138 1,152 1,166 1,181 1,195 1,209 1,223 1,237 1,252 1,266
90 1,280 1,294 1,309 1,323 1,337 1,351 1,365 1,380 1,394 1,408
100 1,422 1,437 1,451 1,465 1,479 1,493 1,508 1,522 1,536 1,550
110 1,565 1,579 1,593 1,607 1,621 1,636 1,650 1,664 1,678 1,693
120 1,707 1,721 1,735 1,749 1,764 1,778 1,792 1,806 1,821 1,835
130 1,849 1,863 1,877 1,892 1,906 1,920 1,934 1,949 1,963 1,977
140 1,991 2,005 2,020 2,034 2,048 2,062 2,077 2,091 2,105 2,119
150 2,134 2,148 2,162 2,176 2,190 2,205 2,219 2,233 2,247 2,262
160 2,276 2,290 2,304 2,318 2,333 2,347 2,361 2,375 2,389 2,404
170 2,418 2,432 2,446 2,460 2,475 2,489 2,503 2,518 2,532 2,546
180 2,560 2,574 2,589 2,603 2,617 2,631 2,646 2,660 2,674 2,688
190 2,702 2,717 2,731 2,745 2,759 2,773 2,788 2,802 2,816 2,830
200 2,845 2,859 2,873 2,887 2,901 2,916 2,930 2,944 2,958 2,973
210 2,987 3,001 3,015 3,030 3,044 3,058 3,072 3,086 3,101 3,115
220 3,129 3,143 3,158 3,172 3,186 3,200 3,214 3,229 3,243 3,257
230 3,271 3,286 3,300 3,314 3,328 3,343 3,357 3,371 3,385 3,399
240 3,414 3,428 3,442 3,456 3,470 3,485 3,499 3,513 3,527 3,542
WA320, 320PZ-6 00-200 39

Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centi-
grade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centi-
grade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C F C F C F C F
40.4 40 40.0 11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
37.2 35 31.0 11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
34.4 30 22.0 10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
31.7 25 13.0 10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
28.9 20 4.0 9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
28.3 19 2.2 8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

27.8 18 0.4 8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
27.2 17 1.4 7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
26.7 16 3.2 7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
26.1 15 5.0 6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
25.6 14 6.8 6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

25.0 13 8.6 5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
24.4 12 10.4 5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
23.9 11 12.2 4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
23.3 10 14.0 3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
22.8 9 15.8 3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

22.2 8 17.6 2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
21.7 7 19.4 2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
21.1 6 21.2 1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
20.6 5 23.0 1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
20.0 4 24.8 0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

19.4 3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
18.9 2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
18.3 1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-200 40 WA320, 320PZ-6

WA320, 320PZ-6 00-200 41

SEN04172-01

2008 KOMATSU
All Rights Reserved
Printed in Japan 08-08 (01)
00-200 42
SEN04173-01
WA320-6
WA320PZ-6
WA320-6 70001 and up

01 Specification 1
100 Specification and technical data

Specification dimension drawing..................................................................................................................... 3
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................... 8
Table of fuel, coolant and lubricants.............................................................................................................. 10
WA320, 320PZ-6 01-100 1

SEN04173-01
01-100 2 WA320, 320PZ-6

Specification dimension drawing SEN04173-01
Specification dimension drawing 1
Item Unit WA320-6 WA320PZ-6

Machine weight (*4) kg 13,665 15,200
Normal load kg 4,480 4,320
Bucket capacity (heaped)(*4) m 3
2.6 2.7
Engine model Komatsu SAA6D107E-1 Diesel engine
Engine rated output
Net [ISO 9249/SAE J1349] (*1) kW{HP}/rpm 125 {167}/2,000
Gross [SAE J1995] (*2) 127.3 {171}/2,000
A Overall length (*4) mm 7,660 7,770
B Overall height mm 3,200 3,200
C Overall height with bucket lifted up mm 5,325 5,475
D Overall width mm 2,590 2,590
E Minimum ground clearance mm 425 425
F Bucket width mm 2,760 2,750
G Dumping clearance (*3) Bucket tip/(*5) mm 2,940/2,740 2,865/2,795
H Dumping reach (*3) Bucket tip/(*5) mm 990/1,125 1,100/1,135
I Bucket dump angle (max. height) degree 45 48
Bucket tip/(*5) mm 6,225/6,310 6,120/6,150
Min. turning radius
Center of outside tire mm 5,380 5,380
Permissible towing load kN {kg} 100 {10,200} 100 {10,200}
1st (forward/reverse) 4.0 13.0/4.0 13.0 4.0 13.0/4.0 13.0
2nd (forward/reverse) 13.0/13.0 13.0/13.0
Travel speed km/h
3rd (forward/reverse) 18.7/18.7 18.7/18.7
4th (forward/reverse) 38.0/38.0 38.0/38.0
*1: Indicates the value at the lowest cooling fan speed.
*2: Indicates the value of the engine alone (without cooling fan).
*3: Indicates the value at the 45 bucket dump angle.
*4: WA320-6: with tooth, WA320PZ-6: with BOC
*5: WA320-6: tooth tip, WA320PZ-6: BOC tip
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of an
independent engine. While, net denotes the value measured of an engine under the condition essentially the same as that
when it is installed on machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
117 kW {156 HP}/2,000 rpm
a BOC: Abbreviation for Bolt-On Cutting edge
WA320, 320PZ-6 01-100 3

SEN04173-01 Specifications
Specifications 1
Machine model name WA320-6 WA320PZ-6

Serial No. 70001 and up 70001 and up
Machine weight kg 13,665 15,200
Weight
Machine weight (front wheel) in

kg 5,825 6,940
SAE travel posture
Machine weight (rear wheel) in
kg 7,840 8,260
SAE travel posture
Bucket capacity (heaped) m3 2.6 2.7
Normal load kg 4,480 4,320
Travel speed
Forward 1st 4.0 13.0 4.0 13.0
Forward 2nd 13.0 13.0
km/h
Forward 3rd 18.7 18.7
Forward 4th 38.0 38.0
Performance
Reverse 1st 4.0 13.0 4.0 13.0

Reverse 2nd 13.0 13.0
km/h
Reverse 3rd 18.7 18.7
Reverse 4th 38.0 38.0
Max. traction force
Forward 120 {12,200} 120 {12,200}
kN{kg}
Reverse 120 {12,200} 120 {12,200}
Gradeability deg. 25 25
Min. turning radius
mm 5,380 5,380
(center of outside tire)
Turning radius (cutting edge/*3),
mm 6,225/6,310 6,120/6,150
SAE travel posture
Overall length (*2) mm 7,660 7,770
Overall width (chassis) mm 2,590 2,590
Bucket width (*2) mm 2,760 2,750
Overall height (cab top) mm 3,200 3,200
Overall height with bucket lifted up mm 5,325 5,475
Wheelbase mm 3,030 3,030
Tread mm 2,050 2,050
Minimum ground clearance mm 425 425
Dimension
Max. hinge pin height mm 3,905 4,005

Dumping clearance (*1)
mm 2,940/2,740 2,865/2,795
(cutting edge/*3)
Dumping reach (*1)
mm 990/1,125 1,100/1,135
(cutting edge/*3)
Steering angle deg. 38.5 (frame stopper 40) 38.5 (frame stopper 40)
Bucket tilt angle
deg. 47/62 47/66
(operating posture/max. height)
Bucket dump angle
deg. 45 48
(max. height)
Digging depth, 10
mm 250/335 330/370
(cutting edge/*3)
*1: Indicates the value at the 45 bucket dump angle.
*2: WA320-6: with tooth, WA320PZ-6: with BOC
*3: WA320-6: tooth tip, WA320PZ-6: BOC tip
01-100 4 WA320, 320PZ-6

Specifications SEN04173-01

Model SAA6D107E-1
4-cycle, water-cooled, in-line vertical, direct injection type
Type
with turbocharger and air-cooled aftercooler
No. of cylinders bore x stroke mm 6 107 x 124
Total piston displacement l {cc} 6.69 {6,690}
Rated output
Net [ISO 9249/SAE J1349] (*1) 125 {167}/2,000
kW{HP}/rpm
Gross [SAE J1995] (*2) 127.3 {171}/2,000
Engine
Performance
Max. torque (*1) Nm{kgm}/rpm 660 {67.3}/1,500

g/kWh
Min. fuel consumption ratio 224 {167}
{g/HPh}
Max. speed at no load rpm 2,250
Min. speed at no load rpm 825
Starting motor 24 V, 5.5 kW
Alternator 24 V, 60 A
Battery (*3) 12 V, 112 Ah x 2 pieces
HST pump
Type Variable displacement swash plate type piston pump
Pump capacity cc/rev 0 110
HST motor 1
Type Variable displacement bent axis type piston motor
Motor capacity cc/rev 0 140
Power train
HST motor 2
Type Variable displacement bent axis type piston motor
Motor capacity cc/rev 59 128
Counter-shaft double acting planetary type, spur gear
Transfer
constant-mesh type, switching between 2 power trains
Reduction gear unit Spiral bevel gear type, splash lubrication type
Differential Straight bevel gear type, torque proportioning
Final drive Planetary gear single reduction type, splash lubrication type
Drive wheel Front and rear wheel drive
Axle
Front axle Fixed frame, semi-float type

Rear axle Center pin support type, semi-float type
Size 20.5 25 12PR
Rim size 25 x 17.00 1.7
Tire
Inflation pressure
Front wheel kPa 330 {3.3}
Rear wheel {kg/cm2} 280 {2.8}
*1:
Indicates the value at the lowest cooling fan speed.
*2:
Indicates the value of the engine alone (without cooling fan).
*3:
The battery capacity (Ah) is indicated in the 5-hour rate value.
a The engine rated output is indicated in the net value and gross value. Gross denotes the rated output measured of an
independent engine. While, net denotes the value measured of an engine under the condition essentially the same
as that when it is installed on machine.
a Following shows the rated output (net) at the maximum cooling fan speed.
117 kW {156 HP}/2,000 rpm
WA320, 320PZ-6 01-100 5

SEN04173-01 Specifications

Braking method 4-wheel brake, independent front and rear wheel brakes
Type of brake Enclosed wet multiple disc type
Main
Drive method Hydraulic drive

Brake
Operating method Foot-operated (with hydraulic booster)

Braking method Transmission output shaft brake
Parking
Type of brake Wet multiple disc type

Drive method Mechanical type
Operating method Manual lever type
Steering
Steering method Articulated chassis type
Drive method Hydraulic drive

Steering pump
Type Gear type
Delivery cm /rev
3
90.7
Work equipment pump
Hydraulic pump
Type Gear type

Delivery cm /rev
3
32.0
Brake and cooling fan pump
Type Gear type
Delivery cm /rev
3
18.1
Transfer lubrication pump
Type Gear type
Delivery cm3/rev 12.0
Type Double-acting piston type
Cylinder bore mm 70
Steering cylinder
Hydraulic equipment
Piston rod outside diameter mm 40

Stroke mm 453
Max. distance between centers
mm 1,271
of pins
Min. distance between centers
mm 818
of pins
Type Double-acting piston type Double-acting piston type
Cylinder bore mm 140 140
Lift cylinder
Piston rod outside diameter mm 75 75

Cylinder
Stroke mm 740 729

mm 1,969 2,056
of pins
mm 1,229 1,327
of pins
Type Double-acting piston type Double-acting piston type
Cylinder bore mm 160 180
Bucket cylinder
Piston rod outside diameter mm 80 110

Stroke mm 532 558
mm 1,559 1,912
of pins
mm 1,027 1,354
of pins
01-100 6 WA320, 320PZ-6

Specifications SEN04173-01

Work equipment control valve
Control valve
Type 2-spool type 3-spool type

Hydraulic equipment
2
Set pressure MPa{kg/cm } 20.6 {210} 20.6 {210}
Steering valve
Type Orbit-roll type
Set pressure MPa{kg/cm2} 20.6 {210}
Cooling fan motor
Motor
Fixed displacement, swash plate, piston type

Type
<with reversible valve and flow control valve>
Motor capacity cm3/rev 14.5
equipment
Parallel movement type

Type of link Z-bar link
Z-bar link
Work
Straight cutting edge with Straight cutting edge with

Shape of bucket cutting edge
tooth BOC
WA320, 320PZ-6 01-100 7

SEN04173-01 Weight table
Weight table 1
k This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Engine (excluding coolant and oil) 625 625
Damper 6 6
Cooling assembly (excluding coolant and oil) 82 82
Radiator 14 14
Oil cooler 14 14
Aftercooler 10 10
Transfer oil cooler 5 5
Cooling fan motor 13 13
HST pump 85 85
HST motor 1 60 60
HST motor 2 64 64
Transfer 250 250
Front drive shaft 18 18
Rear drive shaft 7 7
Front axle
With torque proportioning differential 714 714
With limited slip differential 718 718
Rear axle
With torque proportioning differential 666 666
With limited slip differential 674 674
Axle pivot (Rear axle) 97 97
Wheel [25 x 17.00 1.7] (1 piece) 120 120
Tire [20.5 25 12 PR] (1 piece) 200 200
Hydraulic tank (excluding hydraulic oil) 89 89
4-gear pump 30 30
Work equipment control valve
2-spool valve 65
3-spool valve 91
Work equipment PPC valve
Mono lever type 3
2-lever type 4
Attachment PPC valve 1
Priority valve 6 6
Orbit-roll valve 8 8
Cushion valve 4 4
Charge valve 6 6
Brake valve 10 10
Steering cylinder assembly (1 piece) 23 23
Lift cylinder assembly (1 piece) 109 112
Bucket cylinder assembly 124 206
01-100 8 WA320, 320PZ-6

Weight table SEN04173-01
Unit: kg
Front frame 1,100 1,252
Rear frame 973 973
Counterweight 1,695 1,950
Additional counterweight (1 piece) 255 220
Engine hood (including side panel) 269 269
Fuel tank (excluding fuel) 125 125
Lift arm (including bushing) 915 1,300
Bucket link 43 68
Bell crank 253 300
Bucket
2.6 m3 (including tooth) 1,127
2.7 m3 (including BOC) 1,139
Operator's cab
825 825
(including air conditioner and interior parts)
Operator seat 41 41
Air conditioner unit 5 5
Battery (1 piece) 36 36
WA320, 320PZ-6 01-100 9

SEN04173-01 Table of fuel, coolant and lubricants
Table of fuel, coolant and lubricants 1
a For details of the notes (Note. 1, Note. 2) in the table, see the Operation and Maintenance Manual.
Unit: l
Reservoir Specified capacity Refill capacity
Engine oil pan 25.5 23.0
Transfer case 8 7.2
Hydraulic system 175 89
Axle (front/rear) 24 24
Cooling system 26.5
Fuel tank 245
01-100 10 WA320, 320PZ-6

Table of fuel, coolant and lubricants SEN04173-01
WA320, 320PZ-6 01-100 11

SEN04173-01

2008 KOMATSU
All Rights Reserved
01-100 12
SEN04174-01
WA320-6
WA320PZ-6
WA320-6 70001 and up

10 Structure, function and

maintenance standard 10
100 Engine and cooling system

Engine mount and transfer mount................................................................................................................... 2
Damper ........................................................................................................................................................... 3
Cooling system ............................................................................................................................................... 4
Cooling system hydraulic piping diagram ....................................................................................................... 5
Cooling fan motor............................................................................................................................................ 7
WA320, 320PZ-6 10-100 1

SEN04174-01 Engine mount and transfer mount
Engine mount and transfer mount 1
10-100 2 WA320, 320PZ-6

Damper SEN04174-01
Damper 1
Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit
Distance between HST pump
1 installation surface and boss tip
Adjust
74.9 0.8
Wear on internal teeth of coupling

2 (resin)
Repair limit: 1.0 Replace
3. Coupling Outline
4. Boss q The damper protects the drive systems on and
5. HST pump input shaft after the engine from torsional vibrations by
6. Cover reducing the torsional vibrations of the engine
7. Flywheel due to the fluctuations in torque.
q The power from the engine is transmitted to
coupling (3) through flywheel (7) and torsional
vibrations are absorbed in coupling (3). Then
the power is transmitted to HST pump through
boss (4).
WA320, 320PZ-6 10-100 3

SEN04174-01 Cooling system
Cooling system 1
1. Reservoir tank 5. Aftercooler

2. Oil cooler 6. Transfer oil cooler
3. Radiator cap 7. Cooling fan
4. Radiator 8. Cooling fan motor
Specifications
Radiator Oil cooler Aftercooler

CF68-4 CF40-1 AL WAVE
Core type
<CF73> <CF74-1> <CF75>
3.5/2 3.5/2 4.0/2
Fin pitch (mm)
<8.0/2> <8.0/2> <8.0/2>
Total heat dissipation area 35.03 4.84 x 3 12.79
(m2) <24.36> <3.25 x 3> <9.69>
Pressure valve cracking pressure 70.0

(kPa {kg/cm2}) {0.7}
Vacuum valve cracking pressure 0 5.0

(kPa {kg/cm2}) {0 0.05}
Values in < > are shown for wide core type (if equipped).
10-100 4 WA320, 320PZ-6

Cooling system hydraulic piping diagram SEN04174-01
Cooling system hydraulic piping diagram 1
1. Cooling fan motor Outline

2. Strainer q Cooling fan motor (1) installed in the machine
3. Hydraulic tank rear side is driven by oil pressure from brake
4. Brake and cooling fan pump and cooling fan pump (4).
5. Charge valve
WA320, 320PZ-6 10-100 5

SEN04174-01 Cooling system hydraulic piping diagram
10-100 6 WA320, 320PZ-6

Cooling fan motor SEN04174-01
Cooling fan motor 1
Type: LMF16
P: From pump through charge valve Specifications

T: To hydraulic tank through return filter Type: LMF16
TC: To hydraulic tank Capacity: 14.5 cm3/rev
Rated speed: 1,800 rpm
1. ER terminal Rated flow rate: 26.1 l/min
2. EF terminal
3. Solenoid proportional pilot valve
4. ON/OFF pilot valve
WA320, 320PZ-6 10-100 7

SEN04174-01 Cooling fan motor
10-100 8 WA320, 320PZ-6

1. Output shaft
2. Case
3. Thrust plate
4. Shoe
5. Piston
6. Cylinder block
7. Valve plate
8. End cover
9. Bearing
10. Center spring
11. Retainer shoe
12. Retainer guide
13. Bearing
14. Oil seal
15. Flow control spool
16. Suction safety valve
17. Reversible spool
Unit: mm
No. Item Criteria Remedy

Free length x
Installed
Outside Installed load Free length Installed load
18 Spool return spring diameter
length If damaged or
deformed, replace
58.8 N 47.1 N spring
44.84 x 12 33
{6 kg} {4.8 kg}
44.1 N 35.3 N
19 Spool return spring 35 x 8.5 34
{4.5 kg}

{3.6 kg}
WA320, 320PZ-6 10-100 9

1. Hydraulic motor
Function
q This hydraulic motor is called a swash plate
axial piston motor. It converts the energy of the
pressurized oil sent from the hydraulic pump
into rotary motion.
Principle of operation
q The pressurized oil from the hydraulic pump
flows through valve plate (7) into cylinder block
(5).
q This pressurized oil flows to the only one side
of the (Y - Y) line connecting the top dead cen-
ter and bottom dead center of the stroke of pis-
ton (4).
q The pressurized oil sent to one side of cylinder
block (5) pushes piston (4) (2 or 3 pistons).
q A single piston generates the force F1 [F1 (kg)
= P (kg/cm2) x xD2/4 (cm2)].
q This force works on thrust plate (2).
q Since thrust plate (2) is fixed to the specific
angle (a) to output shaft (1), the force is
divided into components (F2) and (F3).
q The radial component (F3) generates torque (T
= F3 x ri) against the (Y -Y) line connecting the
top dead center and bottom dead center.
q The result of this torque [T = s (F3 x ri)] rotates
cylinder block (5) through piston (4).
q This cylinder block (5) is connected to output
shaft (1) with the spline.
q Output shaft (1) rotates to transmit the torque.
10-100 10 WA320, 320PZ-6

1) Suction function (2) When the pump is stopped

q When the engine stops, the input revolution of
Function the pump becomes 0 rpm.
q If the fan pump stops, the pressurized oil does q The pressurized oil from the pump is not sup-
not flow into the motor. plied to port (P).
q Since the motor continues revolution because q As the pressurized oil is not supplied to (MA)
of the force of inertia, however, the pressure on side of the motor, the motor speed lowers
the outlet side of the motor rises. gradually to stop.
q When the pressurized oil stops flowing in from q If the motor shaft is revolved by the force of
inlet port (P), suction safety valve (1) sucks in inertia while the oil flow in port (P) is reducing,
the pressurized oil on the outlet side and sup- the oil in port (T) on the outlet side is sent by
plies it to port (MA) where there is not sufficient suction safety valve (1) to (MA) side to prevent
oil to prevent cavitation. cavitation.
Operation
(1) When pump is started
q The pressurized oil from the pump is supplied
to port (P), increasing the (MA) side pressure.
q The starting torque is generated in the motor,
the motor starts revolution.
q The pressurized oil on motor outlet (MB) side
of the motor returns through port (T) to the
tank.
WA320, 320PZ-6 10-100 11

2) Safety function
Function
q When the engine is started, the pressure in
port (P) of the fan motor is heightened in some
cases.
q Suction safety valve (1) is installed to protect
the fan system circuit.
Operation
q If the pressure in port (P) rises above the
cracking pressure of suction safety valve (1),
valve (2) of suction safety valve (1) opens to
release the pressurized oil into port (T).
q By this operation, generation of abnormally
high pressure in port (P) is prevented.
10-100 12 WA320, 320PZ-6

3. Operation of reversible valve
1) When the ON/OFF solenoid is 2) When the ON/OFF solenoid is energized

de-energized q When ON/OFF solenoid (1) is "energized",
q When ON/OFF solenoid (1) is "de-energized", valve (2) is switched.
the pressurized oil from the pump is shut off by q The pressurized oil from the pump flows to
valve (2). spool chamber (D) through port (C).
q Port (C) opens for the hydraulic tank circuit. q The pressurized oil in chamber (D) com-
q Spool (3) is pushed to the right by spring (4). presses spring (4).
q Port (MA) opens and pressurized oil flows in to q Spool (3) moves to the left.
revolve the motor in forward (clockwise). q Port (MB) opens and pressurized oil flows in to
rotate the motor in reverse (counterclockwise).
WA320, 320PZ-6 10-100 13

4. Flow control valve

(continuously-variable type)
Function
This valve supplies the necessary pump delivery to
the motor, and returns the excessive oil to the
hydraulic tank.
q The motor speed increases in proportion to the

increase of the incoming oil (Q) as shown in
Fig. 1.
q When the incoming flow rate is (Q1), motor
speed becomes (B) rpm.
q In order to reduce noise and loss of the motor,
this valve keeps the fan speed constant inde-
pendent of the flow rate to the motor.
q Even if the flow rate is increased from (Q0) to
(Q1), the valve maintains the motor speed con-
stant between points (A) and (C).
Operation
q For the flow control valve, the upstream pres-
sure of the orifice is conducted to the right side
of spool (1) and the downstream pressure of
the orifice is led to its left side.
q The differential pressure before and after ori-
fice (E) by the incoming flow rate to the motor
works on spring (2).
q In Fig. 1, when the flow rate (Q0) is increased
beyond, the differential pressure before and
after spool (1) becomes larger than the
installed load of spring (2).
q Spool (1) moves to the left and port (P) is con-
nected to port (T).
q The excessive oil in (Z) portion of Fig. 1 flows
to the hydraulic tank through the flow control
valve, and the motor speed is kept constant
from (A) to (C).
q This flow control valve is a continuously-vari-
able type.
q As shown in Fig. 2, it is possible to change the
flow control valve continuously while maintain-
ing the motor speed constant between (A') to
( C ') by c ha n g i n g t h e c o m m an d c u r r e n t
between the motor speed (A) and (C).
10-100 14 WA320, 320PZ-6

WA320, 320PZ-6 10-100 15

SEN04174-01

2008 KOMATSU
All Rights Reserved
10-100 16
SEN04175-01
WA320-6
WA320PZ-6
WA320-6 70001 and up


200 Power train

Power train...................................................................................................................................................... 3
Power train system diagram ........................................................................................................................... 4
Drive shaft....................................................................................................................................................... 6
HST hydraulic piping diagram......................................................................................................................... 7
HST pump....................................................................................................................................................... 8
HST motor..................................................................................................................................................... 16
Transfer......................................................................................................................................................... 22
Clutch solenoid valve .................................................................................................................................... 33
Axle ............................................................................................................................................................... 34
Differential ..................................................................................................................................................... 36
Torque proportioning differential ................................................................................................................... 41
Limited slip differential .................................................................................................................................. 44
Final drive ..................................................................................................................................................... 48
WA320, 320PZ-6 10-200 1

200 Power train
SEN04175-01
10-200 2 WA320, 320PZ-6

200 Power train
Power train SEN04175-01
Power train 1
1. Engine
2. Damper
3. HST pump
4. 4-gear pump
5. High-pressure hose
6. HST motor 1
7. HST motor 2
8. Transfer
9. Front drive shaft
10. Front axle
11. Rear drive shaft
12. Rear axle
WA320, 320PZ-6 10-200 3

200 Power train
SEN04175-01 Power train system diagram
Power train system diagram 1
10-200 4 WA320, 320PZ-6

200 Power train
Power train system diagram SEN04175-01
1. Engine Outline
2. Damper q The power from engine (1) is transmitted to
3. HST pump HST pump (3) after its torsional vibrations have
4. Steering pump been reduced with damper (2) installed on the
5. Work equipment pump flywheel.
6. Brake and cooling fan pump q The power from engine (1) is also transmitted
7. Transfer lubrication pump to HST pump (3) and the HST charge pump
8. High-pressure hose being built in HST pump (3) as well as steering
9. HST motor 1 pump (4), work equipment pump (5), brake
10. HST motor 2 and cooling fan pump (6) and transfer lubrica-
11. Emergency steering valve (if equipped) tion pump (7) being connected to HST pump
12. Transfer (3).
13. Transfer clutch q The directional selector valve and servo piston
14. Parking brake installed on HST pump (3) continuously modify
15. Front drive shaft the oil discharge direction and discharged
16. Front axle amount responding to inclination of the swash
17. Differential plate.
18. Wet multiple disc type brake q HST motors (9) and (10) are installed on trans-
19. Final drive fer (12) and connected to HST pump (3)
20. Front tire through high-pressure hose (8).
21. Rear drive shaft q The hydraulic power from HST pump (3)
22. Rear axle changes the rotating direction and speed of
23. Differential HST m oto rs (9) and (1 0) to cont ro l th e
24. Wet multiple disc type brake machine forward and reverse travel and travel
25. Final drive speed.
26. Rear tire q The power from HST motor 1 (9) is transmitted
to the output shaft through transfer clutch (13)
in transfer (12).
The power from HST motor 2 (10) is transmit-
ted to the output shaft through the gear in
transfer (12).
q As the parking brake lever is operated, parking
brake (14) being contained in the rear side of
transfer (12) activates the wet multiple disc
type brake to stop the machine.
q The power to the front side is transmitted to
front axle (16) through front drive shaft (15).
The power to the rear side is transmitted to
rear axle (22) through rear drive shaft (21).
q Speed of the power transmitted to axles (16)
and (22) is reduced on the pinion gear of differ-
entials (17) and (23), then transmitted to the
sun gear through the sun gear shaft.
q Speed of the power transmitted to the sun gear
is reduced on the planetary mechanism of final
drives (19) and (25), then transmitted to tires
(20) and (26) through the axle shaft and wheel.
WA320, 320PZ-6 10-200 5

200 Power train
SEN04175-01 Drive shaft
Drive shaft 1
1. Front axle Outline

2. Front drive shaft q The power from the transfer output shaft is
3. Transfer transmitted to front axle (1) and rear axle (5)
4. Rear drive shaft through front drive shaft (2) and rear drive
5. Rear axle shaft (4).
q When the machine is articulated or when it
receives traveling impacts or working impacts,
the distances between the transfer and the
front and rear axles change. The drive shafts
absorb fluctuations in the angle and length with
the universal joints and slip joint so that the
power will be transmitted without damaging the
parts even when the machine is exposed to
above impacts or changes in the component
positions.
10-200 6 WA320, 320PZ-6

200 Power train
HST hydraulic piping diagram SEN04175-01
HST hydraulic piping diagram 1
1. Hydraulic tank
2. HST pump
3. Clutch solenoid valve
4. HST oil filter
5. HST motor 1
6. HST motor 2
WA320, 320PZ-6 10-200 7

200 Power train
SEN04175-01 HST pump
HST pump 1
a HST: Abbreviation for HydroStatic Transmission
1. Directional selector solenoid valve Specifications

2. High-pressure cutoff valve
Model name A4VG125DA
3. Speed-related valve (DA valve)
4. Charge pump Variable displacement
Type swash plate type piston
5. Low-pressure relief valve pump
6. Servo cylinder Theoretical delivery
7. High-pressure relief valve 0 110
(cc/rev)
8. Control plate High-pressure relief valve
9. Cylinder block set pressure 44.1 {450}
10. Piston (MPa {kg/cm2})
11. Swash plate High-pressure cutoff valve Effective differential
set pressure pressure
(MPa {kg/cm2}) 41.2 {420}
Low-pressure relief valve
set pressure 2.94 {30}
(MPa {kg/cm2})
10-200 8 WA320, 320PZ-6

200 Power train
HST pump SEN04175-01
Operation
Flow of power Flow of oil
q The HST pump is installed on the damper of q Inclination of swash plate (11) starts reciprocat-
the engine flywheel. ing movement of piston (10). The pumping
q The power from the engine is transmitted to action initiated by this reciprocating movement
the HST pump through the flywheel and suctions or discharges the oil in cylinder block
damper. (9) continuously.
q The HST pump is equipped with directional q The pumping action directs the oil flow in a cer-
selector solenoid valve (1) and servo cylinder tain definite direction so that it may flow to the
(6). HST motor.
q Driving the machine forward or reverse acti- q Reversing the inclination of swash plate (11)
vates directional selector solenoid valve (1), reverses the suction and discharge ports and,
tilting swash plate (11) and, as a result, caus- as a result, reversing the oil discharging direc-
ing the switch between the oil suction and dis- tion, too.
charge ports. q Piston (10) does not stroke when swash plate
q The HST pump is built-in cylinder block and 9 (11) is at neutral, thus the oil is not discharged.
pistons (10) rotate along with drive shaft (12). q Increasing or decreasing the inclination (angle)
q Tips of piston (10) slides on the swash plate of swash plate (11) changes the stroke of pis-
surface of swash plate (11) that does not ton (10), allowing to control the travel speed.
rotate. q If the amount of the oil in the low-pressure cir-
cuit (the oil to be returned from the motor to the
pump) becomes insufficient due to leakage of
oil in the HST pump, HST motor and control
valve, the charge pump supplies the oil
through speed-related valve (3) and the check
valve on high-pressure relief valve (7).
WA320, 320PZ-6 10-200 9

200 Power train
High-pressure relief valve 1
1. Nut Function
2. Locknut q This valve is installed on the HST pump. If the
3. Poppet spring oil pressure on the high pressure circuit side
4. Check spring across the HST pump and HST motor goes
5. Main piston beyond the set pressure, it drains the pressure
6. Valve seat to the low pressure circuit side.
7. Pilot poppet This valve sets the maximum pressure of the
8. Adjustment screw HST circuit in this manner to protect the circuit.
q If low level of the oil is detected in the circuit,
the valve conducts oil from the HST charge
pump in order to protect cavitation.
10-200 10 WA320, 320PZ-6

200 Power train
Operation
q Port (A) is connected to the high pressure cir- q As the oil pressure in chamber (B) goes lower,
cuit side of the HST pump, and ports (C) and the orifice of main piston (5) is activated and
(D) are connected to the low pressure circuit differential pressure is generated in port (A)
side of the pump. and chamber (B).
q Oil fills up chamber (B) after flowing through q The oil pressure in port (A) pushes main piston
the orifice of main piston (5). (5) in the left direction, relieving the abnormal
q Pilot poppet (7) is seated on valve seat (6). pressure generated in port (A) to port (C).
q If oil pressure in port (A) and chamber (B) goes q As the oil pressure in port (A) goes lower than
beyond the set pressure, pilot poppet (7) is that in port (C), check spring (4) pushes back
pushed in the left direction. As a result, the oil main piston (5) in the right direction.
pressure in chamber (B) is released to port (C) q The oil in port (C) is conducted to port (A)
through chamber (D) and the oil pressure in through chamber (D) so that the oil level in port
chamber (B) is decreased. (A) may not go low.
q Increasing or decreasing the repulsive force of
poppet spring (3) allows adjusting the set pres-
sure.
q When increasing the set pressure, remove the
nut to loosen the locknut and screw the adjust-
ment screw. When decreasing, loosen the
adjustment screw.
WA320, 320PZ-6 10-200 11

200 Power train
Low-pressure relief valve 1 q When increasing the set pressure, loosen lock-
nut (1) and screw adjustment screw (2). When
decreasing, loosen the adjustment screw.
1. Locknut
2. Adjustment screw
3. Piston
4. Spring
Function
q This valve is installed on the HST pump. If the
oil pressure on the low pressure circuit side
across the HST pump and HST motor goes
beyond the set pressure, it drains the oil to the
hydraulic tank.
This valve sets the oil pressure of the HST
pump charge circuit in this manner to protect
the circuit.
Operation
q Port (A) is connected to the HST pump charge

circuit and port (B) is connected to the drain
circuit.
q As long as port (A) is below the set pressure,
oil does not flow to port (B).
q If oil pressure in port (A) goes beyond the set
pressure, piston (3) is pushed in the right direc-
tion. As a result, the oil pressure in port (A) is
released to port (B) and the oil pressure in port
(A) is decreased.
q Increasing or decreasing the repulsive force of
spring (4) allows adjusting the set pressure.
10-200 12 WA320, 320PZ-6

200 Power train
HST charge pump 1
1. Cover bolt Specifications

2. Pump gear Gear pump
3. Key Type
(inscription type)
4. Coupling Theoretical delivery
28.3
5. Drive shaft (cc/rev)
6. Plate
7. Charge pump cover
8. Crescent separator plate Function
q This pump is connected to the HST pump drive
Outline shaft (5) with coupling (4). Pumping action is
q This pump is installed on the HST pump. It, turned on as it is rotated.
working in conjunction with the HST pump, q It contains pump gear (2) and crescent separa-
supplies oil to the HST speed-related valve tor plate (8) to suction or delivery oil continu-
and the low-pressure relief valve on the HST ously in the direction shown in the figure.
pump.
WA320, 320PZ-6 10-200 13

200 Power train
Speed-related valve (DA valve) 1
1. Locknut
2. Adjustment screw
3. Poppet spring
4. Spring seat
5. Pilot poppet
Function
q It diverges the oil from the HST charge pump
into 2 parts. One part flows to the directional
selector solenoid valve and other part flows to
the low-pressure relief valve.
Operation
q Port (A), port (D) and port (C) are connected to
the HST pump charge circuit, low-pressure
relief valve circuit and directional selector sole-
noid valve circuit, respectively.
q The oil from the HST charge pump constantly
flows to the low-pressure relief valve circuit
through port (A), orifice of pilot poppet (5),
chamber (B) and port (D).
q Orifice of pilot poppet (5) applies to the oil
pressure from the HST charge pump. As the
result, the differential pressure is generated in
port (A) and chamber (B).
q Oil pressure in port (A) pushes pilot poppet (5)
in the left direction to flow the oil in chamber
(B) to the directional selector solenoid valve
circuit through port (C).
q A set of pilot poppet (5) is consisted of poppet
spring (3) and spring seat (4).
q When decreasing the set pressure, loosen
locknut (1) and screw adjustment screw (2).
When increasing, loosen the adjustment
screw.
10-200 14 WA320, 320PZ-6

200 Power train
High-pressure cutoff valve 1
1. Adjustment screw
2. Locknut
3. Spring
4. Spool
5. Piston
6. Barrel
7. Shuttle spool
8. Valve seat
Function
q This valve is installed on the HST pump. If the
oil pressure on the high pressure circuit side
across the HST pump and HST motor goes
beyond the set pressure, it drains the oil in the
servo cylinder circuit to the hydraulic tank.
This valve sets the maximum pressure of the
HST pump circuit in this manner to protect the
circuit.
Operation
q Port (A), port (B), port (Pc) and port (T) are
connected to the high pressure circuit in the
reverse travel, high pressure circuit in the for-
ward travel, speed-related valve circuit and
drain circuit, respectively.
q As oil pressure in (A) side goes high, shuttle
spool (7) is pushed down and closes the port
(B) side circuit.
q Oil pressure on port (A) side pushes up piston
(5) and, at the same time, pushes up spool (4),
too, by compressing spring (3).
q Port (Pc) and port (T) are opened, releasing
abnormal pressure generated in port (Pc) to
port (T).
q As oil pressure in port (Pc) goes low, the
swash plate angle of the HST pump is
reduced. As a result, the pump delivery is
reduced and the HST pump circuit is pro-
tected.
WA320, 320PZ-6 10-200 15

200 Power train
SEN04175-01 HST motor
HST motor 1
a HST: Abbreviation for HydroStatic Transmission
HST motor 1
1. Drive shaft Specifications

2. Piston Model name A6VM140EP
3. Cylinder block
Variable displacement bent
4. Port plate Type axis type piston motor
5. EP servo valve Theoretical delivery
(cc/rev) 0 140
High-pressure relief valve
(MPa {kg/cm2})
High-pressure cutoff Effective differential pressure
valve set pressure 40.7 {415}
(MPa {kg/cm })2

(MPa {kg/cm2})
10-200 16 WA320, 320PZ-6

200 Power train
HST motor SEN04175-01
HST motor 2
1. Drive shaft Specifications

2. Piston Model name A6VM140HA
3. Cylinder block
Variable displacement bent
4. Port plate Type
axis type piston motor
5. HA servo valve Theoretical delivery
6. Directional shuttle valve 59 128
(cc/rev)
High-pressure relief valve
(MPa {kg/cm2})
High-pressure cutoff
Effective differential pressure
valve set pressure
40.7 {415}
(MPa {kg/cm2})
(MPa {kg/cm2})
WA320, 320PZ-6 10-200 17

200 Power train
Principle Operation
q It is assumed that the shaft of the disc is sup- q Pressurized oil from the HST pump flows to the
ported to enable free rotation of the disc. Force back side of piston (2) through the HST motor
F being applied aslant to the disc is divided inlet port, and is activated by inclination of pis-
into force F1 orthogonal to the disc and force ton (2) and cylinder block (3) as the rotating
F2 that works in the circumferential direction of force of drive shaft (1).
the disc. Force F1 pushes the disc in the axial q As the HST motor is rotated forward or
direction and force F2 rotates the disc clock- reverse, the oil in the high pressure circuit side
wise. is conducted to the directional shuttle valve (6).
q Also when force F' works on the disc instead of q As a large load is applied to the motor being
force F, it is likewise divided into force F1' and connected to servo valve (5), the pressure dif-
F2'. Force F2' rotates the disc counterclock- ference is generated between the high pres-
wise. sure circuit side and directional shuttle valve
(6), allowing the servo cylinder to increase
inclination of cylinder block (3).
Structure
q 7 pistons (2) are installed on the disc portion of
drive shaft (1) like spherical joints. They are
housed in cylinder block (3) having a certain
angle to drive shaft (1).
q As external load to the HST motor is
increased, servo valve (5) and directional shut-
tle valve (6) work to increase inclination of cyl-
inder block (3) and piston (2), reducing the
revolving speed and increasing the torque.
10-200 18 WA320, 320PZ-6

200 Power train
EP servo valve 1
1. Motor 1 solenoid valve Operation

2. EP servo valve q Suction force F1 of motor 1 solenoid valve (1)
3. Spring and force F2 of spring (3) are applied to EP
4. Servo cylinder servo valve (2).
q When the current value given to motor 1 sole-
Function noid valve (1) is small (when F1 < F2), EP
q This valve is installed on the rear side of HST servo valve (2) conducts the oil pressure on
motor 1. It controls the motor displacement the motor high pressure side circuit to the
depending on the current value given to motor small diameter side (S) of servo cylinder (4)
1 solenoid valve (1). and releases the oil pressure on the large
diameter side (L) to the tank (motor housing).
As the result, the servo cylinder (4) is moved
toward the min side.
q When the current value given to motor 1 sole-
noid valve (1) is large (when F1 > F2), EP
servo valve (2) conducts the oil pressure to the
large diameter side (L) to move servo cylinder
(4) toward the max side using the difference in
area between the large diameter and small
diameter side (S).
q Magnitude of spring (3) force varies depending
on the position of servo cylinder (4) (motor dis-
placement).
q The current value given to motor 1 solenoid
valve (1) controls the motor displacement to
the position where suction power F1 and
spring force F2 balance.
WA320, 320PZ-6 10-200 19

200 Power train
HA servo valve 1
1. Motor 2 solenoid valve Operation

2. HA servo valve q If the load to the motor is small, HA servo valve
3. Servo cylinder (2) conducts oil pressure to the small diameter
side (S) through the directional shuttle valve
Function and releases the oil pressure on the large
q This valve is installed in the rear side of HST diameter side (L) to the tank (motor housing).
motor 2. In order to bring out the motor output Servo cylinder (3) moves toward the min side,
corresponding to the external load to the minimizing the motor displacement.
motor, it controls the motor displacement using q If a large load is applied to the motor during, for
the oil pressure of the circuit being selected instance, uphill travel, HA servo valve (2) is
from the directional shuttle valve. switched to conduct the oil pressure from the
directional shuttle valve to the large diameter
side (L). As a result, the difference in area
between the large diameter side (L) and small
diameter side (S) moves servo cylinder (3)
toward the max side. The motor displacement
becomes the maximum and generates large
torque.
q As motor 2 solenoid valve (1) is energized, HA
servo valve (2) conducts the oil pressure from
the directional shuttle valve to the large diame-
ter side (L) independent of the magnitude of
the load to the motor to set the motor displace-
ment to the maximum.
10-200 20 WA320, 320PZ-6

200 Power train
Directional shuttle valve 1
1. Directional selector solenoid valve

2. Directional shuttle valve
Function
q This valve is installed in the rear side of HST
motor 2. It controls the destination of the oil
pressure to work on the HA servo valve refer-
encing the incoming signal, which corresponds
to the directional signal of the directional selec-
tor solenoid valve on the HST pump.
Above process reduces the decelerating
impacts that results when the oil pressure is
switched.
Operation
q Directional selector solenoid valve (1) inter-
locks with the directional selector valve on the
HST pump, since it has received the signal that
is corresponding to the directional signal to be
sent to the directional selector solenoid valve
on the HST pump.
q Directional shuttle valve (2) is activated by
directional selector solenoid valve (1) and con-
trols the destination of the oil pressure to work
on the HA servo valve.
WA320, 320PZ-6 10-200 21

200 Power train
SEN04175-01 Transfer
Transfer 1
a: Clutch port
b: Lubrication inlet port
c: Lubrication suction port
1. HST motor 2 mounting section

2. HST motor 1 mounting section
3. Oil filler pipe
4. Transfer
5. Parking brake lever
6. Speed sensor
10-200 22 WA320, 320PZ-6

200 Power train
Transfer SEN04175-01
1. HST motor 1 9. Sun gear (number of teeth: 37)

2. Input shaft 10. Parking brake
3. Transfer clutch 11. Rear coupling
4. Carrier 12. Output gear (number of teeth: 55)
5. Ring gear (number of teeth: 86) 13. Spacer
6. Planetary pinion (number of teeth: 24) 14. Output shaft
7. Planetary shaft 15. Front coupling
8. Motor 1 gear (number of teeth: 50)
WA320, 320PZ-6 10-200 23

200 Power train
Input shaft
Unit: mm
Standard Tolerance Standard Clearance
Clearance between input shaft and size Shaft Hole clearance limit
1 bearing (front) +0.012 0 0.024
60
0.007 0.012 0.007
Clearance between input shaft 0 +0.016 0.006
2 bearing and cage (front)
95
0.013 0.006 0.029

Clearance between input shaft and +0.011 0 0.023

3 bearing (middle)
50
0.005 0.012 0.005


4 bearing and ring gear (middle)
80
0.013 0.006 0.026

Clearance between input shaft and +0.011 0 0.023

5 bearing (rear)
50
0.005 0.012 0.005

Replace
6 bearing and carrier (rear)
80
0.013 0.006 0.026

Clearance between press fitting +0.039 0 0.054

7 shaft and bearing
55
+0.020 0.015 0.020

Clearance between press fitting 0 0.016 0.038

8 shaft bearing and motor 1 gear
100
0.018 0.038 0.002

Clearance between piston and 0.085 +0.040 0.085

9 spacer
177
0.125 0 0.165

0.550 +0.046 0.550

10 Clearance between piston and cage 222
0.650 0 0.696

11 Clearance between clutch housing

and front case
200
+0.061
+0.015
+0.046
0
0.061
0.031

10-200 24 WA320, 320PZ-6

200 Power train
Unit: mm
Standard size Tolerance Repair limit
Thickness of separator plate
1.7 0.05 1.6
12
Strain on separator plate 0.05 0.15
Thickness of friction plate 2.2 0.08 1.8

13
Strain on friction plate 0.02 0.25
14 Load of wave spring

(height: 2.2 mm)
1,147 N
{117 kg}
115 N
{11.7 kg}
918 N
{94 kg}
Inside diameter of seal ring contact +0.021
25 25.1
surface 0
+0.15
Width of seal ring groove 2.5 2.7
+0.10
15
0.01
Width of seal ring 2.5 2.3
0.03
Thickness of seal ring 1.2 0.1 1.05
Inside diameter of seal ring contact +0.035 Replace

90 90.1
surface 0
+0.15
Width of seal ring groove 3 3.3
+0.10
16
0.01
Width of seal ring 3 2.7
0.03
Thickness of seal ring 3.7 0.12 3.55
Inside diameter of seal ring contact +0.022

120 120.5
surface 0
+0.1
Width of seal ring groove 4.5 5.0
0
17
0
Width of seal ring 4.36 3.9
0.1
Thickness of seal ring 3 0.1 2.7
18 Backlash between motor 1 gear and

output gear
0.190 0.465
Side clearance of planetary gear

(on both sides)
0.35 0.80
WA320, 320PZ-6 10-200 25

200 Power train
Output shaft
10-200 26 WA320, 320PZ-6

200 Power train
Unit: mm
Clearance between output shaft size Shaft Hole clearance limit
1 and bearing (front) +0.030 0 0.045
60
+0.011 0.015 0.011
Clearance between output shaft 0 0.015 0.040
2 bearing and cage (front)
110
0.018 0.040 0.003

Clearance between output shaft +0.030 0 0.045

3 and bearing (rear)
65
+0.011 0.015 0.011

Clearance between output shaft 0 0.015 0.040

4 bearing and rear case (rear)
120
0.018 0.040 0.003

Clearance between oil seal and +0.170 +0.054 0.170

5 cage (front)
100
+0.080 0 0.026

Clearance between dust seal and +0.400 +0.054 0.400 Replace

6 cage (front)
100
+0.200 0 0.146

Clearance between oil seal and +0.170 +0.054 0.170

7 cage (rear)
100
+0.080 0 0.026

Clearance between dust seal and +0.400 +0.054 0.400

8 cage (rear)
100
+0.200 0 0.146

Clearance between output shaft 0 +0.030 0

9 and spacer
60
0.030 0 0.060


10 Outside diameter of coupling oil
seal contact surface (front) 0
75 74.8
0.074
11 Outside diameter of coupling oil

seal contact surface (rear)
75
0
0.074
74.8
Standard size Standard clearance Clearance limit

12 Clearance
case
between cage and front
0.7 0.1 1.3
Adjust with shims
13 Free
shaft
rotational torque of output
3.9 5.9 Nm {0.4 0.6 kgm}
WA320, 320PZ-6 10-200 27

200 Power train
10-200 28 WA320, 320PZ-6

200 Power train
1. HST motor 2
2. Motor 2 gear (number of teeth: 50)
3. Strainer
4. Drain plug
Unit: mm
Clearance between input shaft and size Shaft Hole clearance limit
5 bearing +0.035 0 0.050
65
+0.013 0.015 0.013
Replace
6 bearing and cage
120
0.015 0.013 0.037

Backlash between motor 2 gear and

7 output gear
0.190 0.465
WA320, 320PZ-6 10-200 29

200 Power train
Outline Operation of clutch

q The transfer is equipped with 2 HST motors. It
selects a gear speed out of 1st - 4th speed Clutch is "engaged" (fixed)
both in the forward and reverse travels and
transmits it to the output shaft. It changes the
gear speed by varying output and revolving
direction of the HST motors and combinations
of the transfer clutches.
Relation between transfer clutch and transfer

clutch pressure at respective speed ranges
Speed
Transfer clutch Transfer clutch pressure
range
1st Engaged OFF
2nd Engaged OFF
Travel speed Travel speed Travel speed Travel speed
3rd 0 A km/h A 18.7 km/h 0 A km/h A 18.7 km/h
Engaged Disengaged OFF ON q As the oil from the clutch solenoid valve is cut
Travel speed Travel speed Travel speed Travel speed off, piston (2) is pushed back in the right direc-
4th 0 A km/h A 38 km/h 0 A km/h A 38 km/h tion by the repulsive force of spring (1).
Engaged Disengaged OFF ON q Piston (2) compresses plates (3) and discs (4)
*1: The travel speeds listed above are the ones when the tires and the rotation of discs (4) is stopped by the
of the size 20.5-25 are worn. And value A varies depending frictional force.
on the opening ratio of the accelerator pedal.
q As the internal teeth of disc (4) are meshed
with the external teeth of ring gear (5), ring
Relationship between accelerator pedal angle gear (5) is fixed.
and travel speed (A) for starting transfer clutch
switching modulation Clutch is "disengaged" (released)
Accelerator pedal angle (%)

Transfer clutch
0 65 65 90 90 100
Engaged o
8 km/h 8 10 km/h 10 km/h
Disengaged (B)
Disengaged o 7 km/h 7 9 km/h 9 km/h
Engaged (C)
q The oil from the clutch solenoid valve is pres-

sure-fed to the back side of piston (2), and
pushes piston (2) in the left direction by com-
pressing spring (1).
q Plates (3) and discs (4) are released from the
frictional force, setting ring gear (5) to the neu-
tral position.
q Wave spring (6) is assembled between plates
(3) to accelerate return of piston (2) as the
clutches are released. And at the same time, it
helps smooth separation of plates (3) and
discs (4) in order to prevent drag turning.
10-200 30 WA320, 320PZ-6

200 Power train
Power transmitting route

Low speed mode
Transfer clutch (1) is fixed to transmit power of both HST motor 1 (2) and HST motor 2 (3).
Power of HST motor 1 (2) Power of HST motor 2 (3)

O O
Input shaft (4) O
O O
Sun gear (5) O
O O
Planetary pinion (6) O
O O
Carrier (7) O
O O
Motor 1 gear (8) Motor 2 gear (9)
O O
Output gear (10) i i
O
Output shaft (11)
WA320, 320PZ-6 10-200 31

200 Power train
High speed mode
Transfer clutch (1) is released and, since HST motor 1 (2) stops, it transmits power of HST motor 2 (3) alone.
Power of HST motor 2 (3)

O
Motor 2 gear (9)
O
Output gear (10)
O
Output shaft (11)
10-200 32 WA320, 320PZ-6

200 Power train
Clutch solenoid valve SEN04175-01
Clutch solenoid valve 1
P: From HST charge pump Operation

A: To transfer clutch q When the current value of input signal is large,
T: To drain the transfer clutch drains oil pressure.
q As the current value of input signal becomes
1. Clutch solenoid valve smaller, oil pressure of the transfer clutch goes
2. Plunger higher inversely proportional to the current
3. Coil value.
4. Push pin q If the current value of input signal is further
5. Spring lowered until the oil pressure of the transfer
6. Spool clutch reaches the oil pressure at which oil is
7. Body pressure-fed from the HST charge pump, the
oil pressure of the transfer clutch remains at
this level even if the current value may be fur-
ther decreased.
WA320, 320PZ-6 10-200 33

200 Power train
SEN04175-01 Axle
Axle 1
Front axle 1
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet multiple disc type brake
6. Coupling
7. Oil filler port and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
11. Oil temperature sensor
10-200 34 WA320, 320PZ-6

200 Power train
Axle SEN04175-01
Rear axle 1
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet multiple disc type brake
6. Coupling
7. Oil filler port and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
WA320, 320PZ-6 10-200 35

200 Power train
SEN04175-01 Differential
Differential 1
Front differential 1
1. Pinion (number of teeth: 9)

2. Shaft
3. Bevel gear (number of teeth: 42)
4. Sun gear shaft
5. Bevel pinion (number of teeth: 10)
6. Side gear (number of teeth: 12)
10-200 36 WA320, 320PZ-6

200 Power train
Differential SEN04175-01
Unit: mm
7 Starting torque of bevel gear 6.3 21.1 Nm {0.64 2.15 kgm} (outside of bevel gear) Adjust

8 Thickness of pinion washer
3 0.08 2.8
Replace
9 Thickness of side gear washer 4 0.05 3.8
10 Thickness of shim in differential

side bearing carrier (one side)
0.30 1.25
Adjust
11 Backlash of bevel gear 0.20 0.33
12 End play of pinion

(or starting torque)
0 0.165
(0 65 N {0 6.5 kg} (at cage bolt hole))
Replace

housing and cage assembly
1.07 0.33 Adjust

size Shaft Hole clearance limit
14 Clearance of differential
side bearing Outer race 120
0 0.041 0.076

0.020 0.076 0.021
+0.051 0 0.066
Inner race 75
+0.032 0.015 0.032
0 0.054 0.082
Outer race 140
0.018 0.082 0.036
15 Clearance of bearing on
pinion shaft gear side +0.039 0 0.054
Inner race 65
+0.020 0.015 0.020
0 0.041 0.076
Clearance of bearing on Outer race 120
0.015 0.076 0.026

16 pinion shaft coupling
side +0.039 0 0.054 Replace
Inner race 55
+0.020 0.015 0.020
17 Clearance
spider
between pinion gear and
28
0.06
0.11
+0.10
+0.05
0.11
0.21

Clearance in installation position of

0.110 +0.081 0.110
18 differential housing piston 268.5
0.191 0 0.272

(between housing and piston)
0.100 +0.072 0.100
19 bearing carrier piston 247
0.172 0 0.244

(between piston and carrier)
0 0 0.035
Clearance between Outer race 110
0.015 0.035 0.015
20 drive shaft and cage
bearing +0.021 0 0.033
Inner race 50
+0.002 0.012 0.002
WA320, 320PZ-6 10-200 37

200 Power train
Rear differential 1

2. Shaft
4. Sun gear shaft
5. Bevel pinion (number of teeth: 10)
10-200 38 WA320, 320PZ-6

200 Power train
Differential SEN04175-01
Unit: mm
7 Starting torque of bevel gear 6.3 21.1 Nm {0.64 2.15 kgm} (outside of bevel gear) Adjust

8 Thickness of pinion washer
3 0.08 2.8
Replace
9 Thickness of side gear washer 4 0.05 3.8

side bearing carrier (one side)
0.30 1.25
Adjust
11 Backlash of bevel gear 0.20 0.33
12 End play of pinion

(or starting torque)
0 0.165
(0 65 N {0 6.5 kg} (at cage bolt hole))
Replace

housing and cage assembly
1.07 0.33 Adjust

14 Clearance of differential
side bearing Outer race 120
0 0.041 0.076

0.020 0.076 0.021
+0.051 0 0.066
Inner race 75
+0.032 0.015 0.032
0 0.048 0.088
Outer race 140
0.018 0.088 0.030
15 Clearance of bearing on
pinion shaft gear side +0.039 0 0.054
Inner race 65
+0.020 0.015 0.020
0 0.041 0.076 Replace
Clearance of bearing on Outer race 120
0.015 0.076 0.026

16 pinion shaft coupling
side +0.039 0 0.054
Inner race 55
+0.020 0.015 0.020
17 Clearance
spider
between pinion gear and
28
0.06
0.11
+0.10
+0.05
0.11
0.21


0.110 +0.081 0.110
18 differential housing piston 268.5
0.191 0 0.272

(between housing and piston)
0.100 +0.072 0.100
19 bearing carrier piston 247
0.172 0 0.244

(between piston and carrier)
WA320, 320PZ-6 10-200 39

200 Power train
Outline While machine is traveling straight
q The power from the engine is transmitted to

the front and rear axles through the torque
converter, transmission and drive shaft.
q In each axle, the direction of the power is q While the machine is traveling straight, the
changed by 90 and the speed is reduced by right and left wheels rotate at the same speed.
bevel pinion (1) and bevel gear (5). Then, the Accordingly, pinion (4) in the differential
power is transmitted through pinion (4) to sun assembly does not rotate and the power of car-
gear shafts (2). rier (6) is transmitted through pinion (4) and
q Speed of the power transmitted to the sun gear side gear (3) to right and left sun gear shafts
is further reduced by the final drive of the plan- (2) evenly.
etary gear type, and then transmitted to the
axle shafts and wheels. While machine is turning
q While the machine is turning, the right and left

wheels rotate at different speeds. Accordingly,
pinion (4) and side gear (3) in the differential
rotate and transmit the power of carrier (6) to
sun gear shafts (2), depending on the differ-
ence in rotation speed between the right and
left wheels.
10-200 40 WA320, 320PZ-6

200 Power train
Torque proportioning differential SEN04175-01
Torque proportioning differential 1
Outline Operation
Straight travel (When the road resistances
under both tires are the same)
q When the road resistances under the both tires

are the same, distance (a) from pinion (4) to
the meshing point of left side gear (7) and dis-
tance (b) to the meshing point of right side
gear (3) are the same.
q Accordingly, left traction force (TL) and right
traction force (TR) are balanced.
Travel on soft ground (When the road resis-

tances under both tires are different)
q A 4-wheel-drive wheel loader, as a construc-

tion machine, must naturally work on places
where the ground condition is bad. If its tires
slip in such places, its function lowers and the
lives of the tires are shortened. To solve this
problem, the torque proportioning differential is
used.
q Pinion (4) of this differential has an odd num-
ber of teeth. The meshing points of pinion (4)
and side gears (3) change according to the dif-
ference of the road resistance. Consequently,
the traction forces of the tires on both sides q When the tires slip on soft ground, the side
change. gear of the tire on the less road resistance side
turns forward. As a result, the meshing points
of pinion (4) and the side gears change.
q If left side gear (7) turns forward a little, dis-
tance (a) from the pinion to the meshing point
of the left side gear becomes longer than dis-
tance (b) to the meshing point of the right side
gear, and then (a) and (b) are balanced at a
point where (a) x (TL) = (b) x (TR). The ratio of
(a) : (b) changes up to 1 : 1.38, depending on
the meshing condition.
WA320, 320PZ-6 10-200 41

200 Power train
SEN04175-01 Torque proportioning differential
q Accordingly, the pinion does not run idle and

the drive force is transmitted to both side gears
and the tires do not slip until the ratio of (a) : (b)
becomes 1 : 1.38, or the difference between
the road resistances under both tires becomes
38%.
q The lives of the tires are lengthened 20 - 30%
and the working capacity is increased by the
above effect.
10-200 42 WA320, 320PZ-6

200 Power train
Torque proportioning differential SEN04175-01
WA320, 320PZ-6 10-200 43

200 Power train
SEN04175-01 Limited slip differential
Limited slip differential 1
(If equipped)
1. Plate
2. Disc
4. Washer
6. Bevel pinion
7. Shaft
8. Pressure ring
10. Case
10-200 44 WA320, 320PZ-6

200 Power train
Limited slip differential SEN04175-01
Unit: mm
3
11 Thickness of plate
0.02 2.9
3.1
+0.04
12 Thickness of disc 2.5
0.03
2.45
2
13 Thicknesses of washer 0.05 1.8
2.1
Replace
14 Clearance between disc and plate
(total clearance on both sides)
0.2 0.6
15 End play of side gear in axial

direction (one side)
0.13 0.35
16 Backlash of case and plate 0.1 0.6
17 Backlash of side gear and disc 0.13 0.36

18 Clearance between spider and
differential pinion 0.11 +0.05 0.11
28
0.16 0 0.21
WA320, 320PZ-6 10-200 45

200 Power train
SEN04175-01 Limited slip differential
Operation of limited slip differential While machine is traveling straight

q The power from the transmission is transmitted When the drive forces of the right and left
through bevel gear (9), case (10), pressure wheels are balanced
ring (8), shaft (7), pinion (3) and side gear (5), [When the road conditions (coefficient of friction)
and then divided to the right and left shafts. under both wheels and the wheel loads are even,
q The brake unit consisting of disc (2) and plate and the center of load is at the center of the bucket]
(1) is installed to the back side of side gear (5).
It generates braking torque in proportion to the
torque transmitted from pressure ring (8) to
shaft (7).
q Since the brake torque restricts the rotation of
side gears (5) and case (10), right and left side
gears (5) cannot rotate freely. Thus, the opera-
tion of the differential is restricted.
Mechanism of generation of braking torque by

right and left side gears (5)
q Shaft (7) is supported on the cam surfaces

being provided on the surfaces of pressure
rings (8) that are facing each other.
q The power (= torque) transmitted from pres-
sure rings (8) to shaft (7) is transmitted on the q The power from the transmission is distributed
cam surfaces. Force (Fa) to separate pressure evenly by the differential gears to the right and
rings (8) from each other is generated by incli- left. Under this condition, the slip limits of the
nation of the cam surfaces in proportion to the right and left wheels are the same. Accord-
transmitted torque. ingly, even if the power from the transmission
q Separating load (Fa) acts on the brake on the may exceed the slip limits, both wheels slip
back side of each side gear (5) to generate and the differential does not work.
braking torque. No load is applied to the brake on the back
side of the side gear.
10-200 46 WA320, 320PZ-6

200 Power train
Limited slip differential SEN04175-01
When the drive forces of the right and left Difference in wheel drive force by type of differen-
wheels are unbalanced tials when either wheel slipped
[When the road conditions (coefficient of friction) Wheel drive force
under both wheels and the wheel loads are uneven, (drive force of slipping wheel is 1)
and either wheel slips more easily] Slipping wheel Locked wheel Total (ratio)
Example 1. When either wheel is on soft ground Limited slip
differential 1 2.64 3.64 (1.53)
in digging work (if equipped)
Example 2. When either wheel is on snow and Torque
the other one is on asphalt in snow proportioning
1 1.38 2.38 (1)
removing work differential
(standard)
Example 3. When the right and left wheel loads
Conventional
are unbalanced in travel on a slope 1 1 2 (0.84)
differential
Torque proportioning differential

q On a road where either wheel slips easily, the
drive force of the limited slip differential
increases to 1.53 times of the torque propor-
tioning differential.
Conventional differential
(this is not applied with this machine.)
q On a road where either wheel slips easily, the
drive force of the limited slip differential
increases to 1.82 times of the conventional dif-
ferential.
While machine is turning
q The power from the transmission is evenly q The same gears as that for the conventional
divided between the right and left by the differ- differential are employed for the limited slip dif-
ential gear. If, however, the divided drive force ferential. Thus, they allow to smoothly gener-
exceeds the wheel slip limit of the slip side, ate a difference in rotation speed between the
surplus of the driving force is transmitted to the outer and inner wheels that is necessary for
opposite side (lock side) brake through the tuning.
brake and case on the gear back side. Then
the power is distributed to the lock side wheel.
q The differential starts working only as the sur-
plus portion of the drive force has exceeded
the braking force.
WA320, 320PZ-6 10-200 47

200 Power train
SEN04175-01 Final drive
Final drive 1
Front final drive 1
1. Planetary gear (number of teeth: 26)

2. Planetary carrier
3. Axle shaft
4. Ring gear (number of teeth: 69)
5. Sun gear shaft (number of teeth: 15)
10-200 48 WA320, 320PZ-6

200 Power train
Final drive SEN04175-01
Rear final drive 1
1. Planetary gear (number of teeth: 26)

3. Axle shaft
4. Ring gear (number of teeth: 69)
5. Sun gear shaft (number of teeth: 15)
WA320, 320PZ-6 10-200 49

200 Power train
SEN04175-01 Final drive
Unit: mm
Clearance between planetary gear size Shaft Hole clearance limit
6 bearing and shaft +0.025 +0.013 0.025 Replace
33.338
+0.013 0 0
Clearance between axle housing +0.10 +0.10 0.06
7 and ring gear
316
+0.03 +0.04 +0.07

Clearance between oil seal and

8 housing
Max. 0.2 Adjust
+0.4 +0.063 0.4

Housing 155
Press fitting part of axle +0.2 0 0.137
9 shaft seal 0 0.2 0.4
Shaft 115
0.054 0.4 0.146
+0.025 0.012 0.077
Clearance of press Outer race 152.4
0 0.052 0.012
10 fitting part of axle Replace
housing bearing +0.073 +0.025 0.073
Inner race 92.075
+0.051 0 0.026
0 0.038 0.078
Clearance of press Outer race 130
0.025 0.078 0.013
11 fitting part of axle
housing bearing +0.035 0 0.055
Inner race 85
+0.013 0.020 0.013
12 End play of axle shaft 0 0.1 Adjust
+0.025 +0.207 0.120

13 Clearance of guide pin 12
+0.007 +0.145 0.200
Replace
a Starting force of axle housing, see "Disassembly and assembly of axle housing" in Disassembly and
assembly.
10-200 50 WA320, 320PZ-6

200 Power train
Final drive SEN04175-01
Outline
a The figure shows the front axle.

q The final drive finally reduces speed of the
power from the engine to increase the drive
force.
q Ring gear (4) is press fitted to the axle housing
and fixed with the pin.
q Speed of the power being transmitted from the
differential through sun gear shaft (5) is
reduced by the planetary gear unit to increase
the drive force.
The increased drive force is transmitted
through planetary carrier (2) and axle shaft (3)
to the tire.
WA320, 320PZ-6 10-200 51

SEN04175-01

2009 KOMATSU
All Rights Reserved
10-200 52
SEN04176-01
WA320-6
WA320PZ-6
WA320-6 70001 and up


300 Steering system

Steering piping diagram .................................................................................................................................. 3
Steering column .............................................................................................................................................. 4
Priority valve ................................................................................................................................................... 5
Orbit-roll valve................................................................................................................................................. 8
Cushion valve ............................................................................................................................................... 16
Steering cylinder ........................................................................................................................................... 17
Emergency steering piping diagram ............................................................................................................. 19
Emergency steering valve............................................................................................................................. 20
Steering relief valve....................................................................................................................................... 23
WA320, 320PZ-6 10-300 1

300 Steering system
SEN04176-01
10-300 2 WA320, 320PZ-6

300 Steering system
Steering piping diagram SEN04176-01
Steering piping diagram 1
1. Steering cylinder (right)

2. Orbit-roll valve
3. Hydraulic tank
4. Priority valve
5. Steering pump
6. Cushion valve
7. Steering cylinder (left)
WA320, 320PZ-6 10-300 3

300 Steering system
SEN04176-01 Steering column
Steering column 1
1. Steering wheel
2. Steering column
3. Orbit-roll valve
4. Steering tilt lock lever
Unit: mm
Clearance between steering shaft size Shaft Hole clearance limit
5 and column bushing
Replace
0 +0.15 0.05
19 0.4
0.08 +0.05 0.23
10-300 4 WA320, 320PZ-6

300 Steering system
Priority valve SEN04176-01
Priority valve 1
P: From steering pump LS: From Orbit-roll valve

CF: To Orbit-roll valve T: To hydraulic tank
EF: To work equipment control valve
1. Relief valve body 7. Plug

2. Spring seat 8. Valve body
3. Spring 9. Spool
4. Poppet 10. Spring
5. Seat 11. Plug
6. Screen
Unit: mm
Installed Installed Installed
Free length Free length
length load load
12 Control spring
187 14.7 N
187 N Replace
63.4 47.6 63.4 1 {19.1 1.5
{19.1 kg}
kg}
146 14.7 N
146 N
13 Relief spring 31 26.9
{14.9 kg}
{14.9 1.5
kg}
WA320, 320PZ-6 10-300 5

300 Steering system
SEN04176-01 Priority valve
Outline Operation
q The priority valve is installed between the
steering pump and Orbit-roll valve and work When steering wheel is at "neutral" position
equipment control valve. It diverges the oil
from the steering pump to the steering circuit
or work equipment circuit. It is also used for
controlling the oil pressure from the priority
valve to the Orbit-roll valve in order to protect
the circuit.
Set pressure: 21.0 MPa {210 kg/cm2}
q When the engine is stopped, spool (3) is

pushed in the left direction by the repulsive
force of spring (4). Thus, port (M) and port (N)
are fully opened and port (M) and port (Q) are
closed.
q Starting the engine starts the steering pump
rotation, and the oil from the pump flows to port
(A) of the Orbit-roll valve through port (M) and
port (N).
q The oil that flew to chamber (P) through orifice
(m) of spool (3) pushes spool (3) in the right
direction by compressing spring (4).
q Port (M) and port (Q) are opened and port (M)
and port (N) are almost closed to stabilize
spool (3).
q Most of the oil from the pump flows to the work
equipment circuit through port (Q).
10-300 6 WA320, 320PZ-6

300 Steering system
Priority valve SEN04176-01
When steering wheel is "turned left" When steering cylinder is at stroke end
q Turning the steering wheel left changes the q Trying to continuously turn the steering wheel
angle between the sleeve and spool on the after the steering cylinder has reached the
Orbit-roll valve, switching flow of the oil. (see stroke end increases oil pressure in port (S).
"Orbit-roll valve".) q As the oil pressure in port (S) goes beyond the
q Part of the oil from the pump that has flown to set pressure of relief valve (10), the relief valve
port (A) is then conducted to the R.H. steering (10) releases the oil pressure in port (S) to the
cylinder through port (B) and Gerotor, and the hydraulic tank through port (T).
remaining portion of the oil flows to chamber q It generates differential pressure before and
(R) through orifice (b) and port (J). after orifice (r), breaking down the balance
q Change in the angle between the sleeve and between the difference pressure up to port (A)
spool on the Orbit-roll valve generates a differ- and after port (B) and the repulsive force of
ence pressure between the oil pressure up to spring (4). As a result, oil pressure up to port
port (A) and that after port (B). (A) becomes relatively higher.
q Spool (3) stabilizes at a position where the dif- q As port (A) oil pressure is increased, oil in
ference pressure between that of up to port (A) chamber (P) pushes spool (3) in the right direc-
and after port (B) [chamber (P) pressure - tion by compressing spring (4).
chamber (R) pressure] is balanced with the q Port (M) and port (N) are almost closed, and
repulsive force of spring (4). port (M) and port (N) are nearly fully opened to
q The ratio of diversion is determined by the dis- stabilize spool (3).
placement in angle between the spool and
sleeve on the Orbit-roll valve, namely the
opening ratio of port (A) and port (B). And
changing the operating distance of the steering
wheel enables its stepless adjustment.
WA320, 320PZ-6 10-300 7

300 Steering system
SEN04176-01 Orbit-roll valve
Orbit-roll valve 1
P: From steering pump LS: To priority valve

L: To steering cylinder T: To hydraulic tank
R: To steering cylinder
1. Gland 8. Drive shaft

2. Valve body 9. Sleeve
3. Check valve 10. Spool
4. Gerotor 11. Center pin
5. Spacer 12. Centering spring
6. Cover 13. Anti-cavitation valve
7. Spacer 14. Overload relief valve
10-300 8 WA320, 320PZ-6

300 Steering system
Orbit-roll valve SEN04176-01
Outline Structure
q The Orbit-roll valve is connected to the drive q Top (A) of spool (9) is connected to the drive
shaft of the steering column. It changes the oil shaft of the steering column and further con-
flow from the steering pump to the right or left nected to sleeve (8) through center pin (7)
steering cylinder to decide the travel direction (which is not in contact with spool (9) while the
of the machine. steering wheel is at "neutral") and centering
q The Orbit-roll valve is roughly divided into spring (2).
spool (9) and sleeve (8) that have rotary type q Top (B) of drive shaft (3) is engaged with cen-
direction selecting function and Gerotor (5) ter pin (7) and united with sleeve (8) and the
(combination of rotor (5a) and stator (5b)) that bottom is engaged with the spline of rotor (5a)
operates as a hydraulic motor during the nor- of the Gerotor (5).
mal steering operation and as a hand pump q 4 ports are provided on valve body (4). Each
(the steering wheel's operating effort becomes port is respectively connected to the pump cir-
too high to operate it actually) when the oil is cuit, tank circuit, L.H. steering circuit and R.H.
not supplied because of a trouble of the steer- steering circuit. And the ports of the pump side
ing pump or engine. and tank side are connected by the check
valve in the body. If the pump or engine fails,
the oil can be sucked through this check valve
directly from the tank side.
WA320, 320PZ-6 10-300 9

300 Steering system
Operation
When steering wheel is at "neutral" position
10-300 10 WA320, 320PZ-6

300 Steering system
q When the steering wheel is at "neutral" posi-

tion, centering spring (2) sets center pin (7) to
the center of the oblong hole on spool (9) and
movement of spool (9) and sleeve (8) is
stopped.
q Port (A) from sleeve (8) pump, port (E) to the
Gerotor, port (F) to the R.H. steering circuit and
port (G) to the L.H. steering circuit cut off the
vertical grooves (B), (C) and (D) on spool (9).
q Orifice (b) of port (J) to the priority valve is con-
nected to vertical groove (B) on spool (9).
q Port (K) of sleeve (8) is connected to vertical
groove (M) and port (L) on spool (9).
q Due to connection and disconnection of the
ports and vertical grooves, the oil in the priority
valve being set to the pilot pressure is con-
ducted through port (J), orifice (b), vertical
groove (M) and port (K), then drained from port
(L) to the hydraulic tank.
WA320, 320PZ-6 10-300 11

300 Steering system
When steering wheel is "turned left"
10-300 12 WA320, 320PZ-6

300 Steering system
q As the steering wheel is "turned left", spool (9) When steering wheel is at "stop" position
being connected to the drive shaft of the steer- q As operation of the steering wheel is stopped,
ing column is rotated counterclockwise. angular displacement between spool (9) and
q Since spool (9) and sleeve (8) are connected sleeve (8) disappears and the steering wheel
by centering spring(2), spool (9) compresses is returned to the neutral position by the repul-
centering spring (2). sive force of centering spring (2).
q An angular displacement corresponding to the
amount of compression of centering spring (2)
is generated between spool (9) and sleeve (8).
q Port (A) and vertical groove (B) are connected
first being followed by the connection between
vertical groove (B) and port (E), port (E) and
vertical groove (C), and vertical groove (C) and
port (G) to the L.H. steering circuit.
q Although the connection between vertical
groove (B) and orifice (b) of port (J) to the pri-
ority valve is maintained, port (K) of sleeve (8)
starts gradually closing vertical groove (M) and
port (L).
q Port (F) of the R.H. steering circuit is con-
nected to vertical groove (D) at the same time
as port (A) and vertical groove (B) are con-
nected.
q Due to connection and disconnection of the
ports and vertical grooves, the oil from the
pump flows from port (A) to vertical groove (B)
then flows to port (E), starting rotation of the
Gerotor. The oil discharged from the Gerotor
flows to the L.H. steering cylinder head side
through port (E), vertical groove (C) and port
(G).
q Oil pressure of vertical groove (M) is transmit-
ted to port (J) through orifice (b), then supplied
from port (J) as the pilot pressure of the priority
valve.
q The oil from the R.H. steering cylinder head is
drained to the hydraulic tank through port (F),
vertical groove (D) and port (H).
WA320, 320PZ-6 10-300 13

300 Steering system
Connection of hand pump and sleeve
q Above figure shows the suction and discharge q The internal gear of the Gerotor advances by 1
ports (P) of the Gerotor and connections with tooth with every 1/7 turn of the steering wheel
the sleeve ports. and discharges the oil from the pump accord-
q If the steering wheel is turned to the right, ports ing to the steering angle of the steering wheel.
(a), (c), (e), (g), (i), and (k) will be connected to Accordingly, the discharge amount varies in
the pump side by the vertical grooves of the proportion to the steering angle of the steering
spool. Likewise, ports (b), (d), (f), (h), (j), and (l) wheel.
are connected to the R.H. steering cylinder
head side.
Under the condition in Fig. 1, ports (1), (2) and
(3) are in the discharge state of the Gerotor
and connected to ports (l), (b), and (d) and the
oil is sent to the steering cylinder. Ports (5), (6),
and (7) are also connected and the oil form the
pump flows in them.
Fig. 2 shows the state that has resulted from
turning the steering wheel by 90 continued for
above condition. Under this state, ports (2), (3),
and (4) are in the suction state and connected
to ports (k), (a), and (c). Ports (5), (6), and (7)
are in the discharge state and connected to
ports (d), (f), and (h).
q As shown above, the ports in the discharge
state of the Gerotor are connected to the ports
being connected to the steering cylinder. The
ports in the suction state are connected to the
pump circuit.
10-300 14 WA320, 320PZ-6

300 Steering system
Role of centering spring
q Centering spring (2) is composed of 4 X-

shaped leaf springs and 2 flat leaf springs and
installed between spool (9) and sleeve (8) as
shown in the figure.
q If the steering wheel is turned, spool (9) com-
presses centering spring (2) and angular dis-
placement (a) is generated between spool (9)
and sleeve (8).
As a result, the ports of spool (9) and sleeve
(8) are connected and the oil is sent to the
steering cylinder. When the steering wheel
stops turning, the Gerotor also stops turning.
Then, the oil is not sent to the steering cylinder
any more and its pressure rises.
To prevent this, when the steering wheel
stopped turning, Gerotor is turned by the reac-
tion force of centering spring (2) by angular
displacement (a) of spool (9) and sleeve (8) to
return the steering wheel to the "neutral" posi-
tion.
WA320, 320PZ-6 10-300 15

300 Steering system
SEN04176-01 Cushion valve
Cushion valve 1
A: From steering cylinder left turning port Outline

AS: From steering cylinder left turning port q If sudden increase or bouncing occurs in oil
B: From steering cylinder right turning port pressure of the steering cylinder circuit, this
BS: From steering cylinder right turning port valve mitigates the impacts by releasing the
highly pressurized oil to instantly to other line.
1. Valve seat
2. Valve body Function
3. Spring q As highly pressurized oil rushed into port (A), it
4. Poppet compresses spring (3) and opens poppet (4) of
5. Orifice port (A) side, then flows through the center
6. Plug groove of spool (8) up to port (B) opening pop-
7. Spring pet (11) of port (B) side.
8. Spool q At the same time, the highly pressurized oil
9. Plug flows to the pressure chamber of plug (6)
10. Spring through orifice (5) of port (A) side. Then over-
11. Poppet coming the port (B) side pressure and repul-
sive force of spring (7), it pushes spool (8) in
the right direction, cutting off the flow of oil from
port (A) to port (B).
q Temporary flow of oil to the cushion valve
works as cushioning effects in mitigating the
steering impacts. After the operation of the
cushion valve is completed, the steering func-
tions as usual.
q If the pressure change on the steering cylinder
circuit is gradual, spool (8) cuts off the circuit
before poppet (4) opens. Thus, the cushion
valve remains inactivated.
10-300 16 WA320, 320PZ-6

300 Steering system
Steering cylinder SEN04176-01
Steering cylinder 1
Unit: mm
Clearance between bushing in size clearance limit
Shaft Hole
1 cylinder rod frame connecting part
and mounting pin 0 +0.180 0.042
40
0.025 +0.042 0.205
Clearance between bushing in
0 +0.180 0.042
2 cylinder bottom frame connecting 40
0.025 +0.042 0.205

Replace
part and mounting pin
Width of boss Width of hinge Standard (a + b) clearance
Connecting part of steering cylinder
3 and front frame Max. 0.5
50 53
(after shim is adjusted)
Connecting part of steering cylinder Max. 0.5
4 and rear frame
50 53
(after shim is adjusted)
WA320, 320PZ-6 10-300 17

300 Steering system
SEN04176-01 Steering cylinder
Unit: mm
Clearance between piston rod and size Shaft Hole clearance limit
1 bushing 0.025 +0.121 0.020
40 0.485
0.064 0.005 0.185 Replace pin and
Clearance between piston rod 0 +0.180 0.042 bushing
2 supporting shaft and bushing
40
0.025 +0.042 0.205
1.0
Clearance between cylinder bottom 0 +0.180 0.042

3 supporting shaft and bushing
40
0.025 +0.042 0.205
1.0
10-300 18 WA320, 320PZ-6

300 Steering system
Emergency steering piping diagram SEN04176-01
Emergency steering piping diagram 1
(If equipped)
1. Steering pump
2. Priority valve
3. Orbit-roll valve
4. Check valve
5. Emergency steering valve
6. HST motor 2
7. Pressure switch (for detecting emergency steering operation)
8. Steering relief valve
9. Pressure switch (for detecting low oil pressure on steering)
WA320, 320PZ-6 10-300 19

300 Steering system
SEN04176-01 Emergency steering valve
Emergency steering valve 1
(If equipped)
PP: From steering pump 1. Check valve body

A: To HST motor 2 port A 2. Check valve
B: To HST motor 2 port B 3. Valve body
Y: To Orbit-roll valve 4. Pressure reducing valve
S: From hydraulic tank 5. Selector valve
G: To pressure switch
10-300 20 WA320, 320PZ-6

300 Steering system
Emergency steering valve SEN04176-01
Operation
When engine and steering pump are normal
q As long as the engine and steering pump are

operating normally, the oil being pressure-fed
from the steering pump flows to the Orbit-roll
valve, enabling the steering.
q The oil from the steering pump flows to port
(PP), pushes spool (1) in the left direction, then
cuts off the circuit from the HST motor to the
Orbit-roll valve.
WA320, 320PZ-6 10-300 21

300 Steering system
SEN04176-01 Emergency steering valve
When engine or steering pump is abnormal
q If, during travel, the steering pump fails to sup-

ply sufficient amount of oil to the Orbit-roll
valve due to a trouble on the engine or steering
pump, discharge pressure of the steering
pump goes low. As a result, spool (1) is
pushed back in the right direction by the repul-
sive force of spring (2).
q The high pressure side is selected for the oil
from the HST pump at check valves (3) and
(4), and the oil pressure is decreased to an
appropriate level at pressure reducing valve
(5).
q De-pressurized oil flows through port (Y) to the
Orbit-roll valve, enabling the steering.
q If the oil in the HST circuit goes low because of
flowing out to the steering circuit, oil is supplied
to the HST circuit by check valves (6) and (7).
a Thanks to the function of check valves (3) and

(4), the emergency steering system is operable
both in the forward and reverse travel.
10-300 22 WA320, 320PZ-6

300 Steering system
Steering relief valve SEN04176-01
Steering relief valve 1
(If equipped)
P1: From steering pump Outline

P2: From emergency steering pump q The steering relief valve is installed to the right
T: Drain side of the transmission and used to hold the
S1: Steering pump oil pressure switch steering oil pressure to the set pressure.
S3: Emergency steering oil pressure switch Set pressure: 1.96 MPa {20 kg/cm2}
(cracking pressure at 0.5 l/min)
1. Block
2. Relief valve
3. Orifice
WA320, 320PZ-6 10-300 23

SEN04176-01

2009 KOMATSU
All Rights Reserved
10-300 24
SEN04177-00
WA320-6
WA320PZ-6
WA320-6 70001 and up


400 Brake system

Brake piping diagram ...................................................................................................................................... 3
Charge valve ................................................................................................................................................... 4
Brake valve ..................................................................................................................................................... 8
Inching valve ................................................................................................................................................. 12
Accumulator (for brake) ................................................................................................................................ 13
Slack adjuster ............................................................................................................................................... 14
Brake............................................................................................................................................................. 16
Parking brake control .................................................................................................................................... 21
Parking brake ................................................................................................................................................ 22
WA320, 320PZ-6 10-400 1

400 Brake system
SEN04177-00
10-400 2 WA320, 320PZ-6

400 Brake system
Brake piping diagram SEN04177-00
Brake piping diagram 1
1. Hydraulic tank 8. Strainer

2. Brake valve 9. Slack adjuster (for front left side)
3. Brake and cooling fan pump 10. Front brake
4. Rear brake 11. Slack adjuster (for front right side)
5. Accumulator (for front side) 12. Slack adjuster (for rear right side)
6. Accumulator (for rear side) 13. Slack adjuster (for rear left side)
7. Charge valve
WA320, 320PZ-6 10-400 3

400 Brake system
SEN04177-00 Charge valve
Charge valve 1
10-400 4 WA320, 320PZ-6

400 Brake system
Charge valve SEN04177-00
P: From brake and cooling fan pump

T: To hydraulic tank
A: To cooling fan motor
ACC1: To accumulator (rear side)
ACC2: To accumulator (front side)
S: Brake operation sensor port
G: Gauge port
1. Valve body
2. Inverse shuttle valve
3. Plunger
4. Unload relief valve
5. Unload valve
6. Relief valve
Unit: mm
Clearance between inverse shuttle size Shaft Hole clearance limit
7 valve and body 0.006 +0.011 0.006
12 0.029
0.014 0 0.025
Clearance between plunger and 0.005 +0.009 0.005
8 body
8
0.012 0 0.021
0.024
Clearance between unload valve 0.006 +0.011 0.006

9 and body
18
0.017 0 0.028
0.032

Installed Installed Installed
Free length Free length Replace
10 Inverse shuttle valve return spring length load load
9.8 N 8.3 N
21.6 18.3
{1.0 kg} {0.85 kg}
11 Unload
(inside)
relief valve return spring
35.9 30.0
188 N
{19.2 kg}

160 N
{16.3 kg}
Unload relief valve return spring 137 N 116 N
12 (outside) 39.8 27.5
{14.0 kg}

{11.8 kg}
49 N 42 N
13 Unload valve return spring 51.6 45.0
{5.0 kg}

{4.3 kg}
4.9 N 4.2 N
14 Check valve return spring 11.5 9.0
{0.5 kg}

{0.43 kg}
Function
q The charge valve maintains the oil pressure
from the pump to the set pressure and accu-
mulates it in the accumulator.
q If the oil pressure from the pump goes beyond
t h e re lie f va lv e s e t p r e ss u re , th is va lv e
releases the oil pressure to the drain circuit in
order to reduce the load to the pump.
WA320, 320PZ-6 10-400 5

400 Brake system
SEN04177-00 Charge valve
Operation
When oil is not supplied to accumulator When oil is supplied to accumulator
(cut-out state) 1. Cut-in state
q Plunger (1) is moved in the left direction by the q As the accumulator pressure goes low, pres-
accumulator pressure, and maintains unload sure on port (E) goes low, allowing plunger (1)
relief valve (2) being pushed open. to move in the right direction and unload relief
q The oil in the spring chamber of unload valve valve (2) to close the drain circuit.
(3) is drained to the hydraulic tank through port q Since the oil pressure in port (F) and the spring
(F), unload relief valve (2) and port (T). chamber of unload valve (3) increases, unload
q Since oil pressure in port (F) is decreased, valve (3) moves in the right direction.
unload valve (3) moves in the left direction q Port (C) and port (B) are opened, conducting
being subjected to the action of the oil from the oil from the pump to port (B).
chamber (B). q As oil pressure in port (B) increases beyond
q Port (C) and port (D) are opened, supplying the set pressure of check valve (4), check
most of the oil from the pump to the cooling fan valve opens, allowing the oil to be supplied to
motor through port (P), ports (C) and (D), and the accumulator through port (E). The pressure
port (A). for supplying oil to the accumulator depends
on the set pressure of check valve (4).
q Amount of oil supplied to the accumulator is
constant independent of the engine speed,
thus surplus of the oil flows to the cooling fan
motor through port (A).
q Inverse shuttle valve (5) supplies precedence
to the accumulator of lower pressure when
supplying oil.
10-400 6 WA320, 320PZ-6

400 Brake system
Charge valve SEN04177-00
When the oil pressure from the pump went

2. When pressure reaches cut-out pressure beyond the set pressure
q As pressure in port (F) reaches the set pres- q As oil pressure in chamber (B) reaches the set
sure (cut-out pressure of unload relief valve pressure of relief valve (6), relief valve (6) is
(2)), oil in the spring chamber of unload valve opened to drain the oil from the pump to the
(3) is drained to the hydraulic tank through port hydraulic tank through port (T).
(F), unload relief valve (2) and port (T). Above process protects the brake circuit by
q Plunger (1) is moved in the left direction by the restricting its maximum pressure.
accumulator pressure, and maintains unload
relief valve (2) being pushed open.
q Since oil pressure in port (F) is decreased,
unload valve (3) moves in the left direction
being subjected to the action of the oil from
chamber (B).
q Port (C) and port (D) are opened, supplying
most of the oil from the pump to the cooling fan
motor through port (P), ports (C) and (D), and
port (A).
WA320, 320PZ-6 10-400 7

400 Brake system
SEN04177-00 Brake valve
Brake valve 1
P1: From HST pump A: To Rear brake

T1: To hydraulic tank PB: From accumulator (front side)
T2: To steering pump (suction side) B: To front brake
PA: From accumulator (rear side)
1. Rod 5. Brake valve body (for rear)

2. Inching valve spool 6. Brake valve spool (for front)
3. Inching valve body 7. Brake valve body (for front)
4. Brake valve spool (for rear)
Unit: mm
Clearance between inching valve size Shaft Hole clearance limit
8 spool and body 0.022 +0.033 0.020
22.4 0.096
0.053 0 0.086
Clearance between inching valve 0.022 +0.033 0.020
9 guide and body
22.4
0.053 0 0.086
0.096
Clearance between inching valve 0.050 +0.050 0.050

10 spool and guide 12
0.093 0 0.143
0.157

Installed Installed Installed Replace
Free length Free length
11 Inching valve control spring length load load
24.5 N 20.8 N
34.7 16.7
{2.5 kg} {2.1 kg}
113 N 96 N
12 Brake valve control spring 35.6 24.0
{11.5 kg}

{9.8 kg}
19.6 N 16.7 N
13 Inching valve return spring 50.0 49.5
{2.0 kg}

{1.7 kg}
147 N 125 N
14 Brake valve return spring 114.9 52.4
{15.0 kg}

{12.7 kg}
10-400 8 WA320, 320PZ-6

400 Brake system
Brake valve SEN04177-00
Outline
q The brake valve is installed in the lower front
side of the operator's seat. Pressing the brake
pedal conducts oil to the brake piston, operat-
ing the brake.
q The left side and right side brake pedals are
mechanically interlocked. Pressing one of the
pedals operates another pedal at the same
time.
q The brake valve contains the inching valve to
regulate the control pressure of the HST pump.
Operation
When the brake pedal is pressed down
q Brake pedal (1) pressing effort is transmitted to When brake of one side is operated
spool (5) through rod (2), spool (3) and spring (when the other brake failed)
(4). q Even when only one side of the brakes
q As spool (5) is pushed in the right direction, remains operable due to, for instance, oil leak
port (Ta) is closed and the oil from the pump on the front or rear brake system, brake pedal
activates the rear brake after being conducted (1) pressing effort moves in the right direction
through the accumulator, port (PA), port (A) after being transmitted mechanically through
and rear brake piston. spool (5) and spool (6).
q As spool (5) is pushed in the right direction, q Oil from the pump is conducted normally to the
spool (6) is also pushed in the right direction, brake piston of the healthy system to enable
closing port (Tb). The oil from the pump flows stopping the machine as needed in order to
through the accumulator, port (PB) and port (B) ensure safety.
to the front brake piston to activate the front
brake.
WA320, 320PZ-6 10-400 9

400 Brake system
SEN04177-00 Brake valve
Balancing operation
q As the rear brake piston is filled with oil and the

oil pressure rises between port (PA) and port
(A), the oil being conducted to chamber (E)
through orifice (c) of spool (5) pushes spool (5)
in the left direction resisting repulsive force of
spring (4). As the result, port (PA) and port (A)
are disconnected.
q Since port (Ta) remains closed, the oil con-
ducted to the brake piston is retained and the
brake remains operable.
q At the same time as spool (5) is moved to the
left, the front brake piston is filled up with oil,
increasing the oil pressure between port (PB)
and port (B). Thus, the oil conducted to cham-
ber (F) through orifice (d) of spool (6) pushes
back spool (6) in the left direction by the move
distance of spool (5). As the result, port (PB)
and port (B) are disconnected.
q Since port (Tb) remains closed, the oil con-
ducted to the brake piston is retained and the
brake remains operable.
q The oil pressure of the rear brake circuit [port
(A) side] is balanced with the brake pedal
pressing effort, and the oil pressure of the front
brake circuit [port (B) side] is balanced with the
oil pressure of the rear brake circuit [port (A)
side].
q As spools (5) and (6) are moved in the right
direction to the stroke end, port (PA) and port
(A) as well as port (PB) and port (B) are fully
connected. As a result, oil pressure of the rear
b ra k e c irc u it a n d t h e fr o nt b r a ke c ir cu it
becomes equal to that from the pump.
q Braking force is adjustable by adjusting the
brake pedal pressing effort until spools (5) and
(6) are driven in the right direction to the stroke
end.
10-400 10 WA320, 320PZ-6

400 Brake system
Brake valve SEN04177-00
When brake pedal is released
q Releasing brake pedal (1) releases the pedal

pressing effort being applied to spool (5).
q Spool (5) is pushed back in the left direction by
the back pressure of the rear brake piston and
repulsive force of spring (7), and port (PA) and
port (A) are closed.
q At the same time, oil in the rear brake piston is
drained to the hydraulic tank through port (A)
and port (Ta), releasing the rear brake.
q At the same time as spool (5) is moved in the
left direction, spool (6) is also pushed back in
the left direction by the back pressure of the
front brake piston and repulsive force of spring
(7). As the result, port (PB) and port (B) are
closed.
q Oil in the front brake piston is drained to the
hydraulic tank through port (B) and port (Tb),
releasing the front brake.
WA320, 320PZ-6 10-400 11

400 Brake system
SEN04177-00 Inching valve
Inching valve 1
P1: From HST pump port Y Outline

T2: To steering pump (suction side) q The inching valve, which is contained in brake
valve (2), reduces the control oil pressure of
1. Brake pedal the HST circuit responding to stroke (S) of
2. Brake valve spool (3) in order to reduce the capacity of the
3. Spool HST pump.
4. Body
10-400 12 WA320, 320PZ-6

400 Brake system
Accumulator (for brake) SEN04177-00
Accumulator (for brake) 1
1. Cylinder
2. Free piston
Function
q The accumulator is installed between the
charge valve and brake valve. The space
between cylinder (1) and free piston (2) is filled
with nitrogen gas. The nitrogen gas absorbs
the hydraulic pulses generated by the hydrau-
lic pump and secures the braking force and
operability when the engine is stopped by uti-
lizing its compressibility.
Specifications
Gas used Nitrogen gas
Amount of gas (cc) 500
Charge pressure 3.5 0.1 {35.7 1}
(MPa {kg/cm 2}) (at 20C)
Max. pressure used
10 {102}
(MPa {kg/cm 2})
WA320, 320PZ-6 10-400 13

400 Brake system
SEN04177-00 Slack adjuster
Slack adjuster 1
A: From brake valve

B: To brake piston
1. Body
2. Check valve
3. Piston
Unit: mm
Clearance between piston and size Shaft Hole clearance limit
4 body
0.065 +0.052 0.065
30 0.098 0 0.150 0.163
Clearance between check valve 0.013 +0.015 0.013

5 and body
10
0.028 0 0.043
0.048
Standard size Repair limit Replace
Free length Installed Installed Free length Installed

6 Piston return spring length load load
11.8 N 9.8 N
87.5 48.2 {1.2 kg} {1.0 kg}
53.9 N 46.1 N
7 Check valve return spring 21.7 19.25
{5.5 kg}

{4.7 kg}
10-400 14 WA320, 320PZ-6

400 Brake system
Slack adjuster SEN04177-00
Function
q The slack adjuster is installed between the
brake valve and brake piston. It maintains the
time lag up to activation of the brake constant.
Operation
When brake is applied When brake is released
q The oil from the brake valve flows to port (A) q The oil being stopped between piston (1) and
and moves piston (1) in the right direction to brake piston pushes back piston (1) in the left
activate the brake using the oil being amassed direction, allowing the oil, equivalent in the vol-
between piston (1) and the brake piston. ume to piston (1) move distance, to return to
q The slack adjuster maintains the time lag up to the brake valve through port (A) then is drained
activation of the brake constant by operating to the hydraulic tank.
t h e b r a k e u s in g t h e o i l b e i n g a m a s s e d
between piston (1) and the brake piston.
q If the oil between piston (1) and brake piston
goes low due to wear on the brake disc and
like, it pushes open check valve (2) to make up
the deficit.
WA320, 320PZ-6 10-400 15

400 Brake system
SEN04177-00 Brake
Brake 1
Front brake 1
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring (2 pieces)
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Disc (2 pieces)
10-400 16 WA320, 320PZ-6

400 Brake system
Brake SEN04177-00
Unit: mm
6.5 0.1 6.0
Thickness of brake disc 8.7 0.15 7.9
11 Depth of lining groove 0.8 0.2 0.4
Thickness of lining 1.0 0.8 (min.) Replace

Standard size Tolerance Wear limit
12 Wear of disc contact surface of
brake outer ring 20.1 0.1 0.3

Load of spring Installed height Installed load Installed load
13 (when 2 pieces are piled)
912 N 730 N
7.6
{93 kg} {74 kg}
Outline
q The front brake is a wet multiple disc type
brake, which consists of piston (3), inner ring
(5), disc (9), outer ring (8), and spring (4).
q The brake cylinder consists of differential
housing (1) and bearing carrier (2). And piston
(3) is assembled to them.
Inner ring (5) and outer ring (8) are coupled
with the spline of differential housing (1).
q Disc (9) has linings stuck to its both sides and
is installed between inner ring (5) and outer
ring (8), and they are coupled together by the
spline of sun gear shaft (6).
WA320, 320PZ-6 10-400 17

400 Brake system
SEN04177-00 Brake
Rear brake 1
1. Differential housing
2. Bearing carrier
3. Piston
4. Spring
5. Inner ring (2 pieces)
6. Sun gear shaft
7. Axle housing
8. Outer ring
9. Disc (2 pieces)
10-400 18 WA320, 320PZ-6

400 Brake system
Brake SEN04177-00
Unit: mm
6.5 0.1 6.0
11 Depth of lining groove 0.8 0.2 0.4
Thickness of lining 1.0 0.8 (min.) Replace

Standard size Tolerance Wear limit
12 Wear of disc contact surface of
brake outer ring 20.1 0.1 0.3
13 Load of spring
(when 2 pieces are piled)
Installed height Installed load Installed load
912 N 730 N
7.6
{93 kg} {74 kg}
Outline
q The rear brake is a wet multiple disc type
brake, which consists of piston (3), inner ring
(5), disc (9), outer ring (8), and spring (4).
q The brake cylinder consists of differential
housing (1) and bearing carrier (2). And piston
(3) is assembled to them.
Inner ring (5) and outer ring (8) are coupled
with the spline of differential housing (1).
q Disc (9) has linings stuck to its both sides and
is installed between inner ring (5) and outer
ring (8), and they are coupled together by the
spline of sun gear shaft (6).
WA320, 320PZ-6 10-400 19

400 Brake system
SEN04177-00 Brake
Operation
When brake is operated
q As the brake pedal is pressed, oil pressure (P)

being supplied through the hydraulic tank,
pump and brake charge valve to the brake cyl-
inder acts on piston (2) in the brake cylinder to
move the piston.
Accordingly, disc (4) between piston (2), inner
ring (3), and outer ring (5) is stopped and the
brake is applied to the machine.
When brake is released
q If the oil pressure is released, piston (2) is

returned to the original position by the return-
ing force of spring (8) and clearance is made
between inner ring (3) and outer ring (5), and
disc (4) becomes free.
The linin gs stu ck to disc (4 ) ha ve cr os s
grooves on them. While disc (4) is rotating, oil
flows in those grooves to cool the linings.
10-400 20 WA320, 320PZ-6

400 Brake system
Parking brake control SEN04177-00
Parking brake control 1
1. Parking brake lever 4. Control cable

2. Parking brake lever bottom switch 5. Transfer
3. Parking brake lever intermediate switch 6. Multi-disc brake lever
Outline
q The parking brake is built in transfer (5). On
this mechanical parking brake, operating the
multi-disc brake lever (6) from parking brake
lever (1) allows "applying" or "releasing" the
parking brake.
q Pulling parking brake lever (1) on the opera-
tor's seat pulls up the multi-disc brake lever
(6), which is connected with control cable (4),
"applying" the parking brake.
q Returning parking brake lever (1) to its original
position pushes down the multi-disc brake
lever (6), which is connected with control cable
(4), "releasing" the parking brake.
q As long as the parking brake is "applied", cur-
rent to the directional solenoid valve on the
HST pump is cut off and the swash plate of the
HST pump is maintained at the neutral posi-
tion.
WA320, 320PZ-6 10-400 21

400 Brake system
SEN04177-00 Parking brake
Parking brake 1
1. Lever 5. Plate
2. Housing 6. Disc
3. Ball 7. Wave spring
4. Piston 8. Output shaft
Unit: mm
Thickness of plate
2.6 0.06 2.5
9
Strain on plate 0.05 0.1
Replace
10
Strain on brake disc 0.02 0.25
11 Load of wave spring

(height: 2.2 mm)
1,010 N
{103 kg}
101 N
{10.3 kg}
858 N
{87.6 kg}
Outline
q This parking brake is a wet multiple disc type
brake being operated mechanically to apply
braking to output shaft (8).
q Lever (1) is connected to the control cable. Ball
(3) provided between piston (4) and housing
(2), that are connected to lever (1), moves on
the slope of the piston groove responding to
the pulling distance of the parking brake lever.
By this move of the ball, piston (4) compresses
plate (5) and disc (6) to each other, thereby
applying brake to output shaft (8).
10-400 22 WA320, 320PZ-6

400 Brake system
Parking brake SEN04177-00
WA320, 320PZ-6 10-400 23

SEN04177-00

2008 KOMATSU
All Rights Reserved
10-400 24
SEN04178-00
WA320-6
WA320PZ-6
WA320-6 70001 and up


500 Undercarriage and frame

Axle mount and center hinge pin .................................................................................................................... 2
Tires ................................................................................................................................................................ 7
WA320, 320PZ-6 10-500 1

SEN04178-00 Axle mount and center hinge pin
Axle mount and center hinge pin 1
a The following drawing shows WA320-6.
10-500 2 WA320, 320PZ-6

Axle mount and center hinge pin SEN04178-00
1. Front axle Outline

2. Tension bolt q Front axle (1) receives the force during work
3. Rear axle directly. Thus, it is fixed directly to front fame
4. Frame lock bar (5) with tension bolt (2).
5. Front frame q Rear axle (3) is designed to sway at the center
6. Center hinge pin of rear frame (7) so that each tire may contact
7. Rear frame the ground surface even when the machine is
8. Additional counterweight traveling on soft ground.
(WA320-6: if equipped) q Front frame (5) and rear frame (7) are coupled
(WA320PZ-6: standard) by the center hinge pin (6) with the bearing
9. Counterweight between them. The right and left steering cylin-
ders connect the front frame (5) and rear frame
(7). They adjust the bending angle or the turn-
ing radius of the frame according to move of
the cylinder.
WA320, 320PZ-6 10-500 3

10-500 4 WA320, 320PZ-6

Axle mount and center hinge pin SEN04178-00
Unit: mm
Clearance between upper hinge pin size Shaft Hole clearance limit
1 and rear frame 0.030 +0.046 0.030
75
0.076 0 0.122
Clearance between upper hinge pin 0.030 +0.250 0.030
2 and spacer (small)
75
0.076 0 0.326

Clearance between upper hinge pin 0.030 0 0.015

3 and bearing
75
0.076 0.015 0.076

Clearance between upper hinge pin 0.030 +0.026 0.010

4 and spacer (large)
75
0.076 0.020 0.102

Clearance between rear frame and 0.010 +0.054 0.010

5 spacer (large)
90
0.040 0 0.094

Clearance between front frame and 0 0.030 0.076

6 upper hinge bearing
120
0.020 0.076 0.010

Clearance between lower hinge pin 0.030 +0.067 0.057 Replace

7 and rear frame bushing
75
0.076 +0.027 0.143

Clearance between lower hinge pin 0.030 0 0.015

8 and bearing
75
0.076 0.015 0.076

Clearance between front frame and 0 0.041 0.076

9 lower hinge bearing
115
0.015 0.076 0.026

10 Clearance
bushing
between rear frame and
85
+0.089
+0.059
+0.054
0
0.089
0.005

11 Clearance of press fitting part of

lower hinge pin seal
90
+0.280
+0.180
+0.054
0
0.280
0.126


12 Height
(small)
of upper hinge spacer
24.5 0.1
13 Height of upper hinge spacer (large) 64.0 0.1
14 Standard thickness of shim

between upper hinge and retainer
2.0

between upper hinge and retainer
1.0

between lower hinge and retainer
1.0
19.6 2.0 Nm {2.0 0.2 kgm} (when shim is adjusted) Adjust

17 Tightening torque of upper hinge
retainer mounting bolt
98 123 Nm {10.0 12.5 kgm} (final value)
19.6 2.0 Nm {2.0 0.2 kgm} (when shim is adjusted)

18 Tightening torque of lower hinge
retainer mounting bolt
98 123 Nm {10.0 12.5 kgm} (final value)
WA320, 320PZ-6 10-500 5

Unit: mm
1 Thickness of thrust plate
22 0.5
+0.3
2 Thickness of thrust washer 5
0.1

Standard Tolerance Standard Clearance Replace

Clearance between shaft and hole size Shaft Hole clearance limit
3 on front support side 0.050 +0.472 0.050
190
0.122 0 0.594
Clearance between shaft and hole 0.005 +0.522 0.055
4 on rear support side
170
0.124 +0.050 0.646

10-500 6 WA320, 320PZ-6

Tires SEN04178-00
Tires 1
The radial tires (if equipped) of this machine have the following features.
q High gripping force q Low fuel consumption
q High operator comfort q Long life
q Less frequency of burst q Less damages of machine
q Less uneven wear q Less generation of heat
Comparison of structures and characteristics of tires

Radial tire Bias tire
Structure Structure
q The cords of carcass (1) are arranged at right q The cords of carcass (1) are arranged bias
angles to the center line of tread (T) (radially). from the center line of tread (T).
q Tread (T) is stabilized and protected by several q Side wall (W) and tread (T) are integral.
strong belts (2).
q Side wall (W) and tread (T) are independent
from each other.
Ground contact characteristics Ground contact characteristics

q Even if the tire is deformed by a load, it does q If the tire is deformed by a load, the ground
not move uselessly in ground contact and uni- contact surface is also deformed, leading to
form ground contact surface is secured stably. wasteful moves. As a result, the ground con-
tact surface becomes unstable.
Deformation characteristics Deformation characteristics

q Only side wall (W) is deformed as load is q Side wall (W) which receives loads and tread
applied and tread (T) made of strong belts (2) (T) move as one unit.
keeps stability independently.
WA320, 320PZ-6 10-500 7

SEN04178-00

2008 KOMATSU
All Rights Reserved
10-500 8
SEN04179-00
WA320-6
WA320PZ-6
WA320-6 70001 and up


600 Hydraulic system

Work equipment hydraulic piping diagram ...................................................................................................... 2
Work equipment control lever linkage ............................................................................................................. 6
Hydraulic tank ............................................................................................................................................... 10
4-gear pump.................................................................................................................................................. 12
Work equipment control valve....................................................................................................................... 14
Cut-off valve .................................................................................................................................................. 40
PPC valve ..................................................................................................................................................... 43
Lock valve ..................................................................................................................................................... 58
Accumulator (for PPC circuit)........................................................................................................................ 59
ECSS valve................................................................................................................................................... 61
Accumulator (for ECSS)................................................................................................................................ 63
WA320, 320PZ-6 10-600 1

SEN04179-00 Work equipment hydraulic piping diagram
Work equipment hydraulic piping diagram 1
WA320-6
10-600 2 WA320, 320PZ-6

Work equipment hydraulic piping diagram SEN04179-00
1. Work equipment control valve Outline

2. Bucket cylinder q The hydraulic system is consisted of the HST,
3. Hydraulic tank steering, work equipment, brake, cooling fan
4. Work equipment PPC valve and transfer lubrication circuit. The work equip-
5. Lock valve ment circuit controls move of the lift arm and
6. Oil cooler bucket.
7. Check valve q The oil in hydraulic tank (3) is supplied to work
8. 4-gear pump equipment control valve (1) by work equipment
Steering pump pump of 4-gear pump (8). When each spool of
Work equipment pump the lift arm and bucket of work equipment con-
Brake and cooling fan pump trol valve (1) is at the Hold position, the oil
Transfer lubrication pump flows the drain circuit of work equipment con-
9. Cut off valve trol valve (1), is filtered on the return filter on
10. Accumulator (for ECSS) (if equipped) hydraulic tank (3), then is returned to hydraulic
11. Lift cylinder tank (3).
12. ECSS valve (if equipped) q Operating the work equipment lever operates
13. Accumulator (for PPC circuit) the lift arm spool or bucket spool of work
equipment PPC valve (4).
The oil from work equipment PPC valve (4)
operates respective spools of work equipment
valve (1) with its oil pressure, then sends the
oil pressure to lift cylinder (11) or bucket cylin-
der (2) to operate the lift arm or bucket.
q The maximum pressure in the hydraulic circuit
is controlled with the relief valve in work equip-
ment control valve (1). The bucket cylinder cir-
cuit is equipped with the safety-suction valve
for protection of the circuit.
q Accumulator (for PPC circuit) (13) is installed
on the PPC pilot circuit so that the work equip-
ment can be lowered to the ground even while
the engine is stopped.
q Hydraulic tank (3) is pressurized, enclosed,
and equipped with the breather having the
relief valve, which doubles the oil filler cap
function. The breather applies pressure to the
tank and, at the same time, prevents genera-
tion of negative pressure in the tank to prevent
cavitation in the pump.
WA320, 320PZ-6 10-600 3

SEN04179-00 Work equipment hydraulic piping diagram
WA320PZ-6
10-600 4 WA320, 320PZ-6

Work equipment hydraulic piping diagram SEN04179-00
1. Work equipment control valve Outline

2. Quick coupler solenoid valve q The hydraulic system is consisted of the HST,
3. Bucket cylinder steering, work equipment, brake, cooling fan
4. Hydraulic tank and transfer lubrication circuit. The work equip-
5. Work equipment PPC valve ment circuit controls move of the lift arm,
6. Attachment PPC valve bucket and attachment.
7. Lock valve q The oil in hydraulic tank (4) is supplied to work
8. Oil cooler equipment control valve (1) by work equipment
9. Check valve pump of 4-gear pump (10). When each spool
10. 4-gear pump of the lift arm, bucket and attachment of work
Steering pump equipment control valve (1) is at the Hold posi-
Work equipment pump tion, the oil flows the drain circuit of work
Brake and cooling fan pump equipment control valve (1), is filtered on the
Transfer lubrication pump return filter on hydraulic tank (4), then is
11. Cut off valve returned to hydraulic tank (4).
12. ECSS valve (if equipped) q Operating the lift arm control lever or bucket
13. Accumulator (for ECSS) (if equipped) control lever operates the lift arm spool or
14. Lift cylinder bucket spool of work equipment PPC valve (5).
15. Coupler plunger If operating the auxiliary control lever operates
16. Accumulator (for PPC circuit) the spool of attachment PPC valve (6).
The oil from work equipment PPC valve (5) or
attachment PPC valve (6) operates respective
spools of work equipment control valve (1) with
its oil pressure, then sends the oil pressure to
lift cylinder (14), bucket cylinder (3) or coupler
plunger (15) to operate the lift arm, bucket or
attachment.
q The maximum pressure in the hydraulic circuit
is controlled with the relief valve in work equip-
ment control valve (1). The bucket cylinder cir-
cuit is equipped with the safety-suction valve
for protection of the circuit.
q Accumulator (for PPC circuit) (16) is installed
on the PPC pilot circuit so that the work equip-
ment can be lowered to the ground even while
q Hydraulic tank (4) is pressurized, enclosed,
and equipped with the breather having the
relief valve, which doubles the oil filler cap
function. The breather applies pressure to the
tank and, at the same time, prevents genera-
tion of negative pressure in the tank to prevent
cavitation in the pump.
WA320, 320PZ-6 10-600 5

SEN04179-00 Work equipment control lever linkage
Work equipment control lever linkage 1
WA320-6
Mono-lever type
1. Work equipment control lever

2. Wrist rest
3. Lock valve
4. Work equipment lock lever
5. Work equipment PPC valve
6. Wrist rest height adjustment lock lever
10-600 6 WA320, 320PZ-6

Work equipment control lever linkage SEN04179-00
WA320-6
2-lever type
(If equipped)
1. Lift arm control lever

2. Bucket control lever
3. Wrist rest
4. Lock valve
WA320, 320PZ-6 10-600 7

SEN04179-00 Work equipment control lever linkage
WA320PZ-6
2-lever type
1. Lift arm control lever

2. Bucket control lever
3. Auxiliary control lever
4. Wrist rest
5. Lock valve
7. Attachment PPC valve
10-600 8 WA320, 320PZ-6

Work equipment control lever linkage SEN04179-00
WA320PZ-6
Multi-function mono-lever type
(If equipped)
1. Work equipment control lever

2. Auxiliary control lever
3. Directional selector switch
4. Wrist rest
5. Lock valve
8. Attachment PPC valve
WA320, 320PZ-6 10-600 9

SEN04179-00 Hydraulic tank
Hydraulic tank 1
1. Oil filler cap and breather Specifications

2. Return filter
Capacity of hydraulic tank (l) 124
3. Hydraulic tank
4. Drain plug Quantity of oil in hydraulic tank (l) 89
5. Sight gauge
6. Return filter bypass valve Set pressure of bypass valve 0.2
(MPa {kg/cm2}) {2.04}
7. Check valve
Cracking pressure of check valve 0.2 0.03
(MPa {kg/cm2}) {1.96 0.29}
10-600 10 WA320, 320PZ-6

Hydraulic tank SEN04179-00
Breather 1
1. Oil filler cap

2. Case
3. Lock-resetting knob
4. Sleeve
5. Poppet
6. Filter element
Prevention of negative pressure in tank

q Since the tank is pressurized and enclosed, if
the oil level in it lowers, negative pressure is
generated.
At this time, sleeve (4) is opened by the differ-
ential pressure between the tank pressure and
the atmospheric pressure to prevent genera-
tion of the negative pressure.
(set pressure of air intake valve:
3.0 0.3 kPa {0.03 0.003 kg/cm2})
Prevention of pressure rise in tank

q While the hydraulic circuit is in operation, the
oil level in the tank rises as the hydraulic cylin-
ders operate, and the temperature rises. Con-
sequently, the pressure in the tank rises, too.
If the pressure in the tank rises beyond the set
level, poppet (5) is activated to release the
pressure in the tank to prevent rise of pressure
in the tank.
(set pressure of exhaust valve:
0.1 0.015 MPa {1.0 0.15 kg/cm2})
WA320, 320PZ-6 10-600 11

SEN04179-00 4-gear pump
4-gear pump 1
(steering, work equipment, brake, cooling fan and transfer lubrication)
Type: SAR(3)90 + (2)32 + SB(1)18 + 12
1. Steering pump Outline

2. Work equipment pump q The 4-gear pump is installed on the HST
3. Brake and cooling fan pump pump. The axial rotation drives this gear to
4. Transfer lubrication pump supply pressurized oil to the steering, work
equipment, brake, cooling fan and transfer.
10-600 12 WA320, 320PZ-6

4-gear pump SEN04179-00
Unit: mm
Type Standard clearance Clearance limit
SAR(3)90
5 Side clearance SAR(2)32
0.10 0.15 0.19
SBR(1)18
SBR(1)12
SAR(3)90 0.083 0.144
Clearance between inside diameter SAR(2)32 0.071 0.121
6 of plain bearing and outside 0.20
Replace
diameter of gear shaft SBR(1)18
0.068 0.115
SBR(1)12
Type Standard size Allowance Repair limit
SAR(3)90 13
0
SAR(2)32 12
7 Pin driven depth 0.5
SBR(1)18 10
+0.5
SBR(1)12 7 0
8 Torque of spline rotating shaft 13.8 28.5 Nm {1.4 2.9 kgm}
Discharge Standard Allowable

Type Speed pressure delivery delivery
(rpm)
(MPa {kg/cm2}) (l/min) (l/min)
Delivery
SAR(3)90 208 192
Oil: SAE10WCD
Oil temperature: 45 55C SAR(2)32 20.6 {210} 72 65
2,500
SBR(1)18 40 35
SBR(1)12 2.9 {30} 27 24
WA320, 320PZ-6 10-600 13

SEN04179-00 Work equipment control valve
Work equipment control valve 1
WA320-6
2-spool type
10-600 14 WA320, 320PZ-6

Work equipment control valve SEN04179-00
A1: To bucket cylinder head

A2: To lift arm cylinder head
B1: To bucket cylinder bottom
B2: To lift arm cylinder bottom
P1: From steering pump
P1A: From PPC valve P1 port
P1B: From PPC valve P3 port
T: Drain port (To tank)
WA320, 320PZ-6 10-600 15

10-600 16 WA320, 320PZ-6

1. Bucket spool
2. Lift arm spool
3. Suction valve
5. Check valve
6. Main relief valve
Unit: mm
Free length x Installed
7 Spool return spring (for bucket)
diameter
length
125 N 100 N
54.8 x 34 53.5
{12.7 kg} {10.2 kg}
Spool return spring 207.9 N 167 N
8 (for bucket and lift arm) 54.8 x 33.7 52.5 {21.2 kg} {17 kg}
Spool return spring 255 N 204 N If damaged or
9 (for bucket and lift arm)
30.7 x 32.5 26.5
{26 kg}

{20.8 kg} deformed, replace
spring
10 Spool return spring
(for lift arm)
51.9 x 16.9 40
182.4 N
{18.6 kg}

146 N
{14.9 kg}

(for lift arm) 87.6 x 34.7 83.5
229.5 N
{23.4 kg}
183 N
{18.7 kg}
44.1 N 35.3 N
12 Check valve spring 32.6 x 10.9 24.5 {4.5 kg} {3.6 kg}
6.4 N 5.1 N
13 Suction valve spring 64.9 x 12.5 56
{0.65 kg}

{0.52 kg}
WA320, 320PZ-6 10-600 17

WA320-6
3-spool type
10-600 18 WA320, 320PZ-6

A1: To attachment cylinder

B1: To attachment cylinder
P1A: From attachment PPC valve
P1B: From attachment PPC valve
T: Drain port (to tank)
WA320, 320PZ-6 10-600 19

10-600 20 WA320, 320PZ-6

1. Attachment spool
2. Bucket spool
3. Lift arm spool
4. Suction valve
5. Safety-suction valve
6. Check valve
Unit: mm
Spool return spring Outside Installed load Free length Installed load
8 (for bucket and attachment) diameter
length
125 N 100 N
54.8 x 34 53.5
{12.7 kg} {10.2 kg}
If damaged or
(for bucket and lift arm)
30.7 x 32.5 26.5
255 N
{26 kg}

204 N
spring
(for lift arm)
51.9 x 16.9 40
182.4 N
{18.6 kg}

146 N
{14.9 kg}

(for lift arm)
87.6 x 34.7 83.5 229.5 N
{23.4 kg}
183 N
{18.7 kg}
44.1 N 35.3 N
6.4 N 5.1 N
{0.65 kg}

{0.52 kg}
WA320, 320PZ-6 10-600 21

WA320PZ-6
2-spool type
10-600 22 WA320, 320PZ-6


T: Drain port (To tank)
WA320, 320PZ-6 10-600 23

10-600 24 WA320, 320PZ-6

1. Bucket spool
2. Lift arm spool
3. Suction valve
5. Check valve
Unit: mm

7 Spool return spring (for bucket)
diameter
length
125 N 100 N
54.8 x 34 53.5
{12.7 kg} {10.2 kg}
8 (for bucket and lift arm)
54.8 x 33.7 52.5
{21.2 kg}

{17 kg}
If damaged or
Spool return spring 255 N 204 N
9 (for bucket and lift arm) 30.7 x 32.5 26.5 {26 kg} {20.8 kg} deformed, replace
spring
(for lift arm)
51.9 x 16.9 40
182.4 N
{18.6 kg}

146 N
{14.9 kg}

(for lift arm)
87.6 x 34.7 83.5
229.5 N
{23.4 kg}

183 N
{18.7 kg}
44.1 N 35.3 N
380 N 304 N
13 Suction valve spring 27.7 x 10.4 25 {38.8 kg} {31 kg}
WA320, 320PZ-6 10-600 25

WA320PZ-6
3-spool type
10-600 26 WA320, 320PZ-6

A1: To attachment cylinder

B1: To attachment cylinder
P1A: From attachment PPC valve
P1B: From attachment PPC valve
T: Drain port (to tank)
WA320, 320PZ-6 10-600 27

10-600 28 WA320, 320PZ-6

1. Attachment spool
2. Bucket spool
3. Lift arm spool
4. Suction valve
5. Safety-suction valve
6. Check valve
Unit: mm
Spool return spring Outside Installed load Free length Installed load
8 (for bucket and attachment) diameter
length
125 N 100 N
54.8 x 34 53.5
{12.7 kg} {10.2 kg}
If damaged or
(for bucket and lift arm)
30.7 x 32.5 26.5
255 N
{26 kg}

204 N
spring
(for lift arm)
51.9 x 16.9 40
182.4 N
{18.6 kg}

146 N
{14.9 kg}

(for lift arm)
87.6 x 34.7 83.5 229.5 N
{23.4 kg}
183 N
{18.7 kg}
44.1 N 35.3 N
376 N 300 N
{38.3 kg}

{30.6 kg}
WA320, 320PZ-6 10-600 29

Relief valve
q If the oil pressure in ports (A) and (B) reaches
the set pressure of pilot poppet spring (4), pilot
poppet (3) opens.
q The oil in port (A) flows through orifice (E) to
ports (B), (D), and (C).
q As a result, differential pressure is made
between ports (A) and (B).
1. Main valve
2. Poppet seat
3. Pilot poppet
4. Spring
5. Adjustment screw
Function
q This valve is installed in the inlet of the work q The differential pressure between ports (A)
equipment control valve. When the oil pressure and (B) pushes main valve (1) open, then the
increases beyond the specified level, it drains oil in port (A) flows through port (C) to the drain
the oil to the hydraulic tank. Above process circuit to let the abnormal pressure escape.
protects the work equipment circuit by restrict- q The set pressure can be changed by increas-
ing the maximum pressure. ing or decreasing the tension of pilot poppet
spring (4).
Operation q To change the set pressure, loosen the lock-
q Port (A) is connected to the pump circuit and nut. Then, tighten or loosen adjustment screw
port (C) is connected to the drain circuit. Oil (5) to heighten or lower the set pressure.
flows through the orifice of main valve (1) and
fills port (B). Pilot poppet (3) is in contact with
(seated on) poppet seat (2).
10-600 30 WA320, 320PZ-6

Safety-suction valve
1. Suction valve
q If abnormal pressure is generated in port (A),
2. Main valve
suction valve (1) does not operate since (d2) >
3. Main valve spring
(d1). At this time, however, main valve (2)
4. Pilot piston
receives oil pressure for the differential area
5. Suction valve spring
between (d3) and (d4) since (d3) of port (A) >
6. Valve body
(d4) of port (C).
q If the abnormal pressure reaches the set pres-
Function
sure of main valve spring (3), main valve (2)
q The safety-suction valve is installed to the operates and the oil in port (A) flows to port
bucket cylinder circuit in the work equipment (B).
control valve. When an impact is applied to the
bucket cylinder and abnormal pressure is gen-
erated while the bucket control lever is in neu-
tral, the safety-suction valve releases the
abnormal pressure to protect the cylinder.
q And if negative pressure is generated in the
cylinder circuit, this valve works as a suction
valve.
Operation
1. Operation as safety valve

q Port (A) and port (B) are connected to the cyl-
inder circuit and drain circuit, respectively.
q The hydraulic oil in port (A) flows through the
hole of pilot piston (4) to port (D). It also flows
through the orifice consisting of main valve (2)
and pilot piston (4) to port (C).
q Pilot piston (4) is fixed to the safety valve and
the order of the diameters (areas) of the sec-
tions is (d2) > (d1) > (d3) > (d4).
WA320, 320PZ-6 10-600 31

2. Operation as suction valve Suction valve

q When negative pressure is generated in port
(A), the pressure in port (D) which is connected
to port (A) becomes negative.
q Since the tank pressure of port (B) is applied to
port (E), the safety valve receives oil pressure
(e) for the differential area between (d2) and
(d1).
q Accordingly, oil pressure (e) is applied in the
opening direction of the valve and oil pressure
(a) is applied in the closing direction of suction
valve (1).
q When the pressure in port (A) lowers and
becomes almost negative, it is lower than oil
pressure (e).
q When oil pressure (e) > oil pressure (a) + force 1. Main poppet
of valve spring (5), suction valve (1) opens and 2. Sleeve
the oil flows through port (B) to port (A), thus 3. Spring
the pressure in port (A) does not become neg-
ative. Function
q This valve prevents to generate negative pres-
sure on the circuit.
Operation
q If negative pressure is generated in port (A) (lift
arm cylinder head) [if a pressure lower than
that in the tank circuit port (B) is generated],
main poppet (1) is opened by the difference in
area between (d1) and (d2), and the pressur-
ized oil flows to cylinder port (A) from tank port
(B).
10-600 32 WA320, 320PZ-6

Operation of work equipment control valve
1. When lift arm and bucket spool are at the neutral position
Operation
q The oil flows from the pump to port (A) and its q The oil from the PPC pump flows in port (L) of
maximum pressure is limited by relief valve (1). the PPC valve. Since the lift arm and bucket
q The bypass circuit of bucket spool (2) is control levers are in the hold positions, how-
opened to hold the lift arm. As a result, the oil ever, the oil returns through the PPC relief
in port (A) flows around the spool into port (B). valve to the hydraulic tank.
q Since lift arm spool (3) is in neutral, its bypass
circuit is open. Accordingly, the oil in port (B)
flows around the spool into the drain circuit and
then returns to the tank.
WA320, 320PZ-6 10-600 33

2. When lift arm spool is at raise position
Operation
q If the lift arm control lever is pulled, the oil flows q The oil in the cylinder head flows through port
from port (L) of the PPC valve through port (N) (E) into drain port (F) and then returns to the
to port (S) of the work equipment control valve. tank. Accordingly, the lift arm is raised.
q The oil in port (T) flows through port (M) to the
drain circuit. The oil in port (S) pushes lift arm
spool (3) to set it in the raise position.
q The oil from the pump flows through the
bypass circuit of bucket spool (2) to the bypass
circuit of spool (3).
q Since the bypass circuit is closed by spool (3),
the oil pushes check valve (5) open.
q Then, the oil flows through port (D) to the cylin-
der bottom.
10-600 34 WA320, 320PZ-6

3. When lift arm spool is at lower position
Operation
q If the lift arm control lever is pushed, the oil q The oil in the cylinder bottom flows through
flows from port (L) of the PPC valve through port (D) into drain port (F) and then returns to
port (M) to port (T) of work equipment control the tank. Accordingly, the lift arm is lowered.
valve.
q The oil in port (S) flows to the drain circuit. The
oil in port (T) pushes lift arm spool (3) to set it
in the lower position.
circuit of spool (3).
q Since the bypass circuit is closed by spool (3),
the oil pushes check valve (5) open.
q The oil flows through port (E) to the cylinder
head.
WA320, 320PZ-6 10-600 35

4. When lift arm spool is at float position
Operation
q If the lift arm control lever is pushed to the float q While the bucket is in contact with the ground,
position, lift arm spool (3) moves over the it can move up and down according to the
lower position to the float position. unevenness of the ground.
circuit of lift arm spool (3).
q The oil in the bypass circuit flows through
spool (3) to the drain circuit and cannot push
check valve (5) open.
q In addition, the lift arm descends by its own
weight since both the raise circuit (D) and
lower circuit (E) of the lift arm cylinder are con-
nected to the drain circuit.
10-600 36 WA320, 320PZ-6

5. When bucket spool is at dump position
Operation
q If the bucket control lever is pushed, the oil in
port (L) of the PPC valve flows through port (Q)
to port (V) of the work equipment control valve.
q The oil in port (R) flows to the drain circuit. The
oil in port (V) sets bucket spool (2) in the dump
position.
q Since the oil from the pump is stopped by
spool (2), the oil from port (A) pushes check
valve (7) open.
q The oil from check valve (7) flows through port
(H) to the bucket cylinder head.
q The oil in the bucket cylinder bottom flows
through port (G) into drain port (F) and then
returns to the tank. Accordingly, the bucket is
dumped.
WA320, 320PZ-6 10-600 37

6. When bucket spool is at tilt position
Operation
q If the bucket control lever is pulled, the oil in
port (L) of the PPC valve flows through port (P)
to port (R) of the work equipment control valve.
q The oil in port (V) flows to the drain circuit. The
oil in port (R) sets bucket spool (2) in the tilt
position.
q Since the oil from the pump is stopped by
spool (2), the oil from port (A) pushes check
valve (7) open.
q The oil from check valve (7) flows through port
(G) to the bucket cylinder bottom.
q The oil in the bucket cylinder head flows
through port (H) into drain port (F) and then
returns to the tank. Accordingly, the bucket is
tilted.
10-600 38 WA320, 320PZ-6

WA320, 320PZ-6 10-600 39

SEN04179-00 Cut-off valve
Cut-off valve 1
a Do not disassemble.
If it is disassembled, its set pressure must be adjusted.
10-600 40 WA320, 320PZ-6

Cut-off valve SEN04179-00
C1: To work equipment control valve T1: To tank

C2: From work equipment control valve T2: To tank
DA: DA port pressure P: From work equipment pump
1. Unload valve 3. Cut-off relief valve

2. Check valve 4. Screen
Unit: mm
5 Unload valve spring
diameter
deformed, replace
36.95 x 12.6 30
{3.6 kg} {2.9 kg}
1.7 N 1.4 N
6 Check valve spring 33 x 13.8 20
{0.17 kg}

{0.14 kg}
Function
q The cut-off valve is installed between the work
equipment pump and work equipment control
valve. It sends the oil from the work equipment
pump to the work equipment control valve or
drains it to control the work equipment speed
according to the working condition.
Operating condition of cut-off valve

q While the engine speed is in the low range, the
cut-off valve operates at low pressure.
WA320, 320PZ-6 10-600 41

SEN04179-00 Cut-off valve
1. When work equipment pump pressure is 2. When work equipment pump pressure is
lower than cut-off pressure higher than cut-off pressure
q Similarly to the state where the work equip- q If the work equipment pump pressure reaches
ment is held, the oil of the work equipment the cut-off pressure, cut-off valve (2) is opened
pump pushes up check valve (1) and merges by the oil pressure in chamber (a) and then the
with the oil from the steering pump and then oil in chamber (b) of unload valve (3) is drained
flows into the work equipment control valve. through chamber (c) of cut-off valve (2).
q Since the oil in chamber (d) of unload valve (3)
flows through orifices (e) and (f) to chamber
(b), the oil pressure in chamber (d) lowers and
unload valve (3) opens.
q Accordingly, the oil from the work equipment
pump is drained.
10-600 42 WA320, 320PZ-6

PPC valve SEN04179-00
PPC valve 1
a PPC: Abbreviation for Proportional Pressure Control
Work equipment PPC valve

Mono-lever type
P: From HST charge pump P3: To lift arm valve (raise)

P1: To bucket valve (tilt) P4: To lift arm valve (lower, float)
P2: To bucket valve (dump) T: To hydraulic tank
WA320, 320PZ-6 10-600 43

SEN04179-00 PPC valve
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Piston
4. Rod 10. Retainer
5. Disc 11. Body
6. Nut (for connecting lever) 12. Filter
10-600 44 WA320, 320PZ-6

Operation
1. When in neutral
1) Bucket PPC valve 2) Lift arm PPC valve

q Ports (PA) and (PB) of the control valve q Ports (PA) and (PB) of the control valve (lift
(bucket valve) and ports (P1) and (P2) of the arm valve) and ports (P3) and (P4) of the PPC
PPC valve are connected through fine control valve are connected through fine control hole
hole (f) of spool (1) to drain chamber (D). (f) of spool (1) to drain chamber (D).
WA320, 320PZ-6 10-600 45

2. When in fine control mode

(neutral o fine control)
q If rod (4) and piston (9) are pushed by disc (5),
retainer (10) is pushed and spool (1) is also
pushed downward through metering spring (2).
q When fine control hole (f) is shut off from drain
chamber (D), almost simultaneously, it is con-
nected to pump pressure chamber (PP).
q The pilot pressurized oil from the HST charge
pump flows through fine control hole (f) and
port (P1) to port (PB).
q If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simul-
taneously to release the pressure in port (P1).
q As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1).
q The positional relationship between spool (1)
and body (11) (where fine control hole (f) is
between drain chamber (D) and pump pres-
sure chamber (PP)) does not change until
retainer (10) comes in contact with spool (1).
q Metering spring (2) is compressed in propor-
tion to the stroke of the control lever.
q Pressure in port (P1) also increases in propor-
q The control valve spool moves to a position
where the pressure in chamber (PB) (equal to
the pressure in port (P1)) is balanced with the
force of the control valve spool return spring.
10-600 46 WA320, 320PZ-6

3. When in fine control mode 4. When lever is operated to stroke end

(when control lever is returned) q Disc (5) and rod (4) push down piston (9) and
q As disc (5) begins to return, the force of center- retainer (10) pushes down spool (1).
ing spring (3) and the pressure in port (P1) q Fine control hole (f) is disconnected from drain
push up spool (1). chamber (D) and connected to the pump pres-
q Because of this, fine control hole (f) is con- sure chamber (PP).
nected to drain chamber (D), and the pressur- q The pilot pressure oil from the HST charge
ized oil at port (P1) is released. pump flows through fine control hole (f) and
q If the pressure in port (P1) went abnormally port (P1) into chamber (PB) to push the control
low, spool (1) is pushed down by metering valve spool.
spring (2). q The oil returning from chamber (PA) flows
q Fine control hole (f) is disconnected from drain through port (P2) and fine control hole (f') into
chamber (D) and almost simultaneously con- drain chamber (D).
nected to the pump pressure chamber (PP).
q The pump pressure is supplied until the pres-
sure in port (P1) recovers to a pressure equiv-
alent to the position of the lever.
q When the control valve spool returns, the pres-
surized oil in drain chamber (D) flows in
through fine control hole (f') of the valve which
is not in operation and flows through port (P2)
into chamber (PA).
WA320, 320PZ-6 10-600 47

5. When lift arm is "float"

q If disc (5) pushes down rod (4) and piston (9)
on port (P4) "lower" side, the detent starts
operation before the stroke end. (the operating
effort of the lever becomes heavy.)
q If rod (4) is pushed down further, the detent
operates to keep the lift arm in "float" state
even if the lever is released.
q At the same time, the control valve is also
moved to the "float" position to keep the lift arm
in float condition.
6. When "float" state of lift arm is reset

q When returning disc (5) from the "float" posi-
tion, the rod is pushed down with a force larger
than absorptive power of the solenoid.
q The "float" state also can be reset and the
lever can be returned to the "neutral" position
by turning off the current in the solenoid (de-
energizing the solenoid).
q The lift arm raise and bucket tilt operations are

carried out similarly to the above.
10-600 48 WA320, 320PZ-6

2-lever type
P: From HST charge pump

P1: To bucket tilt valve
P2: To lift arm LOWER (FLOAT) valve
P3: To lift arm RAISE valve
P4: To bucket DUMP valve
WA320, 320PZ-6 10-600 49

1. Spool 7. Plate
2. Metering spring 8. Piston
3. Centering spring 9. Retainer
4. Rod 10. Body
5. Lever 11. Filter
6. Ring
10-600 50 WA320, 320PZ-6

Operation
1. When in neutral
1) Bucket PPC valve 2) Lift arm PPC valve

q Ports (PA) and (PB) of the control valve q Ports (PA) and (PB) of the control valve (lift
(bucket valve) and ports (P1) and (P4) of the arm valve) and ports (P2) and (P3) of the PPC
PPC valve are connected through fine control valve are connected through fine control hole
hole (f) of spool (1) to drain chamber (D). (f) of spool (1) to drain chamber (D).
WA320, 320PZ-6 10-600 51

2. When in fine control mode

(neutral o fine control)
q If rod (4) and piston (8) are pushed by lever
(5), retainer (9) is pushed and spool (1) is also
pushed downward through metering spring (2).
q When fine control hole (f) is shut off from drain
chamber (D), almost simultaneously, it is con-
nected to pump pressure chamber (PP).
q The pilot pressurized oil from the HST charge
pump flows through fine control hole (f) and
port (P1) to port (PB).
q If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is discon-
nected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simul-
taneously to release the pressure in port (P1).
q As a result, spool (1) moves up and down to
balance the force of metering spring (2) with
the pressure in port (P1).
q The positional relationship between spool (1)
and body (10) (where fine control hole (f) is
between drain chamber (D) and pump pres-
sure chamber (PP)) does not change until
retainer (9) comes in contact with spool (1).
q Metering spring (2) is compressed in propor-
q Pressure in port (P1) also increases in propor-
q The control valve spool moves to a position
where the pressure in chamber (PB) (equal to
the pressure in port (P1)) is balanced with the
force of the control valve spool return spring.
10-600 52 WA320, 320PZ-6

3. When in fine control mode 4. When lever is operated to stroke end

(when control lever is returned) q Lever (5) and rod (4) push down piston (8) and
q If lever (5) begins to return, the force of center- retainer (9) pushes down spool (1).
ing spring (3) and the pressure in port (P1) q Fine control hole (f) is disconnected from drain
push up spool (1). chamber (D) and connected to the pump pres-
q Because of this, fine control hole (f) is con- sure chamber (PP).
nected to drain chamber (D), and the pressur- q The pilot pressure oil from the HST charge
ized oil at port (P1) is released. pump flows through fine control hole (f) and
q If the pressure in port (P1) went abnormally port (P1) into chamber (PB) to push the control
low, spool (1) is pushed down by metering valve spool.
spring (2). q The oil returning from chamber (PA) flows
q Fine control hole (f) is disconnected from drain through port (P4) and fine control hole (f') into
chamber (D) and almost simultaneously con- drain chamber (D).
nected to the pump pressure chamber (PP).
q The pump pressure is supplied until the pres-
sure in port (P1) recovers to a pressure equiv-
alent to the position of the lever.
q When the control valve spool returns, the pres-
surized oil in drain chamber (D) flows in
through fine control hole (f') of the valve which
is not in operation and then flows through port
(P4) into chamber (PA).
WA320, 320PZ-6 10-600 53

5. When lift arm is "float"

q As lever (5) pushes down rod (4) and piston (8)
on port (P3) "lower" side, the detent starts
operation before the stroke end. (the operating
effort of the lever becomes heavy.)
q If rod (4) is pushed down further, the detent
operates to keep the lift arm in "float" state
even if the lever is released.
q At the same time, the control valve is also
moved to the "float" position to keep the lift arm
in float condition.
6. When "float" state of lift arm is reset

q When returning lever (5) from the "float" posi-
tion, the rod is pushed down with a force larger
than absorptive power of the solenoid.
q The "float" state also can be reset and the
lever can be returned to the "neutral" position
by turning off the current in the solenoid (de-
energizing the solenoid).
q The lift arm raise and bucket tilt operations are

carried out similarly to the above.
10-600 54 WA320, 320PZ-6

WA320, 320PZ-6 10-600 55

Attachment PPC valve
a For the details of operation, see the paragraph of "Work equipment PPC valve".
10-600 56 WA320, 320PZ-6

P: From HST charge pump

P1: To attachment valve
P2: To attachment valve
T: To tank
1. Spool
2. Piston
3. Lever
4. Plate
5. Retainer
6. Body
7. Filter
Unit: mm
8 Centering spring
diameter
deformed, replace
41.1 x 15.5 29
{3.7 kg} {2.96 kg}
16.7 N 13.3 N
9 Metering spring 22.73 x 8.1 22 {1.7 kg} {1.36 kg}
WA320, 320PZ-6 10-600 57

SEN04179-00 Lock valve
Lock valve 1
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
Outline
q The lock valve is installed between the HST
charge pump and work equipment PPC valve.
As the work equipment lock lever is set to the
"Lock" position, this valve, in conjunction with
the work equipment lock lever, cuts off the oil
of the PPC circuit to disable the work equip-
ment operation.
10-600 58 WA320, 320PZ-6

Accumulator (for PPC circuit) SEN04179-00
Accumulator (for PPC circuit) 1
1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port
Outline
q The accumulator is installed between the
charge valve and work equipment PPC valve.
Even if the engine stops with the work equip-
ment raised, the pressure of the compressed
nitrogen gas in the accumulator applies the
pilot oil pressure to the work equipment control
valve so that the work equipment will lower by
its weight.
Specifications
Amount of gas (cc) 500
Charged pressure 1.18(+0.2/0) {12(+2/0)}
(MPa {kg/cm2}) (at 80C)
Max. pressure used
3.92 {40}
(MPa {kg/cm2})
WA320, 320PZ-6 10-600 59

SEN04179-00 Quick coupler solenoid valve
Quick coupler solenoid valve 1
WA320PZ-6
P: From work equipment control valve port B2 Outline

T: To work equipment control valve port A2 q When an attachment is installed or removed,
A: To coupler plunger head side the quick coupler solenoid valve changes the
B: To coupler plunger bottom side oil flow for the coupler plunger electrically to
extract or retract the coupler plunger and con-
1. Body nect or disconnect the attachment and quick
2. Solenoid coupler.
3. Check valve 1
4. Check valve 2
10-600 60 WA320, 320PZ-6

ECSS valve SEN04179-00
ECSS valve 1
(If equipped)
a ECSS: Abbreviation for Electronically Controlled Suspension System
P: From work equipment pump

A: From lift cylinder bottom
B: From lift cylinder head
SP: To accumulator (for ECSS)
WA320, 320PZ-6 10-600 61

SEN04179-00 ECSS valve
1. Main spool
2. Solenoid valve
3. Flow control valve
4. Shuttle valve
5. Charge valve
10-600 62 WA320, 320PZ-6

Accumulator (for ECSS) SEN04179-00
Accumulator (for ECSS) 1
(If equipped)
1. Valve
2. Top cover
3. Cylinder
4. Free piston
Function
q The accumulator is installed to the lift cylinder
bottom circuit. The space between cylinder (3)
and free piston (4) is filled with nitrogen gas.
The nitrogen gas absorbs the oil pressure
pulses generated on the lift cylinder bottom
side during travel for higher travel performance
and operating performance by utilizing its com-
pressibility.
Specifications
Amount of gas (cc) 3,000
Charged pressure 2.0 0.1 {20 1}
(MPa {kg/cm2}) (at 20C)
Max. pressure used
20.6 {210}
(MPa {kg/cm2})
WA320, 320PZ-6 10-600 63

SEN04179-00

2008 KOMATSU
All Rights Reserved
10-600 64
SEN04180-02
WA320-6
WA320PZ-6
WA320-6 70001 and up


700 Work equipment

Work equipment linkage ................................................................................................................................. 2
Bucket ............................................................................................................................................................. 6
Bucket positioner and boom kick-out ............................................................................................................ 10
Work equipment cylinder .............................................................................................................................. 22
WA320, 320PZ-6 10-700 1

700 Work equipment
SEN04180-02 Work equipment linkage
Work equipment linkage 1
WA320-6
10-700 2 WA320, 320PZ-6

700 Work equipment
Work equipment linkage SEN04180-02
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
Unit: mm
Clearance between bushing and pin size Shaft Hole clearance limit
7 at each end of bucket link
0.030 +0.174 0.130
75 1.0
0.076 +0.100 0.250
Clearance between bushing and pin 0.030 +0.174 0.130
8 connecting lift arm and bucket
75
0.076 +0.100 0.250
1.0

9 connecting lift arm and frame
85
0.090 +0.120 0.297
1.0
Clearance between bushing and pin

0.036 +0.207 0.156 Replace
10 connecting bucket cylinder bottom 95
0.090 +0.120 0.297
1.0
and frame (Replace pin when
it has scuff marks,
Clearance between bushing and pin too.)
0.036 +0.207 0.156
11 connecting bucket cylinder rod and 95
0.090 +0.120 0.297
1.0
bell crank
12 Clearance between bushing and pin

connecting bell crank and lift arm 110
0.036
0.090
+0.207
+0.120
0.156
0.297 1.0

13 connecting lift cylinder rod and lift 85
0.090 +0.120 0.297
1.0
arm
0.036 +0.207 0.156
14 connecting lift cylinder bottom and 85
0.090 +0.120 0.297
1.0
frame
Width of boss Width of hinge
Standard
Standard Standard clearance
15 Connecting
and frame
part of bucket cylinder size Tolerance size Tolerance
0
90 0.5 93 1.5 1.5 5.0
Adjust shim so that
16 Connecting
frame
part of lift arm and 105 109 1.5 2.5 5.5 clearance will be
below 1.5 mm on
17 Connecting
bucket
part of lift arm and 105 108 +1.5
0
3.0 4.5 each side
18 Connecting
bucket
part of bucket link and
104
+2.8
0.5
109
+1.5
0
2.2 7.0
19 Connecting
frame
part of lift cylinder and 85 0
0.5
89 1.5 2.5 6.0
20 Connecting
bucket link
part of bell crank and 104 +2.8
0.5
109 1.5 0.7 7.0
Replace
21 Connecting
arm
part of bell crank and lift
194 0.5 197 0.5 2.0 4.0
22 Connecting part of bucket cylinder

and bell crank
90 0
0.5
93 1.5 1.5 5.0 Adjust shim so that
clearance will be
below 1.5 mm on
23 Connecting
cylinder
part of lift arm and lift
85 88 1.5 1.5 4.5 each side
WA320, 320PZ-6 10-700 3

700 Work equipment
SEN04180-02 Work equipment linkage
WA320PZ-6
10-700 4 WA320, 320PZ-6

700 Work equipment
Work equipment linkage SEN04180-02
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
7. Quick coupler
Unit: mm
Clearance between bushing and pin size Shaft Hole clearance limit
8 at each end of bucket link
0.036 +0.207 0.156
85 1.0
0.090 +0.120 0.297
0.030 +0.174 0.130
9 connecting lift arm and quick 75 0.076 +0.100 0.250 1.0
coupler

connecting lift arm and frame 85
0.036
0.090
+0.207
+0.120
0.156
0.297 1.0
Clearance between bushing and pin Replace

0.036 +0.207 0.156
11 connecting bucket cylinder bottom 110 0.090 +0.120 0.297 1.0 (Replace pin when
and frame it has scuff marks,
Clearance between bushing and pin too.)
0.036 +0.207 0.156
12 connecting bucket cylinder rod and 110
0.090 +0.120 0.297
1.0
bell crank

connecting bell crank and lift arm
110 0.036
0.090
+0.207
+0.120
0.156
0.297
1.0

14 connecting lift cylinder rod and lift 85
0.090 +0.120 0.297
1.0
arm
15 connecting lift cylinder bottom and 85
0.090 +0.120 0.297
1.0
frame
Width of boss Width of hinge
Standard
Standard Standard clearance
16 Connecting
and frame
part of bucket cylinder size Tolerance size Tolerance
110 0 114 1.5 2.5 6.0

0.5
17 Connecting
frame
part of lift arm and 105 109 1.5 2.5 5.5 Adjust shim so that
clearance will be
18 Connecting
coupler
part of lift arm and quick
105 108
+1.5
0
3.0 4.5 below 1.5 mm on
each side
19 Connecting part of bucket link and
quick coupler
108 1.0 112 +1.5
0
3.0 6.5
20 Connecting
frame
part of lift cylinder and 85 0
0.5
89 1.5 2.5 6.0
21 Connecting
bucket link
part of bell crank and
108 1.0 112 1.5 1.5 6.5
22 Connecting
arm
part of bell crank and lift 194 196 +1.5
0.5
1.5 3.5 Replace
23 Connecting part of bucket cylinder

and bell crank 110
0
0.5 112 1.5 0.5 4.0 Adjust shim so that
clearance will be
below 1.5 mm on
24 Connecting
cylinder
part of lift arm and lift
84 88 1.5 2.5 5.5 each side
WA320, 320PZ-6 10-700 5

700 Work equipment
SEN04180-02 Bucket
Bucket 1
WA320-6
1. Bucket 4. Bucket teeth

2. Wear plate 5. Adapter
3. Bolt-on cutting edge (if equipped)
10-700 6 WA320, 320PZ-6

700 Work equipment
Bucket SEN04180-02
Unit: mm
6 Wear of cutting edge (thickness)
31.8 19
Reverse or replace
7 Wear of cutting edge (length) 90 5
Tooth 46 21
8 Wear of bucket teeth Replace
Tip tooth 48 36
Clearance in adapter mounting

9 parts Max. 0.5 Adjust or replace
WA320, 320PZ-6 10-700 7

700 Work equipment
SEN04180-02 Bucket
WA320PZ-6
1. Bucket 3. Bucket teeth (if equipped)

2. Bolt-on cutting edge 4. Adapter (if equipped)
10-700 8 WA320, 320PZ-6

700 Work equipment
Bucket SEN04180-02
Unit: mm
5 Wear of cutting edge (thickness)
31.8 19
Reverse or replace
6 Wear of cutting edge (length) 90 5
Tooth 46 21
7 Wear of bucket teeth Replace
Tip tooth 48 36
Clearance in adapter mounting

8 parts Max. 0.5 Adjust or replace
WA320, 320PZ-6 10-700 9

700 Work equipment
SEN04180-02 Bucket positioner and boom kick-out
Bucket positioner and boom kick-out 1
WA320-6
1. Bucket positioner proximity switch 4. Bucket cylinder

2. Boom kick-out proximity switch 5. Lift arm
3. Bar 6. Plate
Unit: mm
Clearance on bucket positioner
7 proximity switch
35
Adjust
Clearance on boom kick-out
8 proximity switch
35
10-700 10 WA320, 320PZ-6

700 Work equipment
Bucket positioner and boom kick-out SEN04180-02
Outline
Bucket positioner
q The bucket positioner is driven electrically.
When the bucket is returned to an angle from
the dump position to the tilt position, the bucket
positioner returns the work equipment (bucket)
control lever from the "tilt" position to the "hold"
position to automatically stop the bucket at a
proper digging angle.
q Bar (3) is fixed to the rod side of bucket cylin-
der (4). And proximity switch (1) is fixed to the
cylinder side.
q Moving the work equipment (bucket) control
lever from "dump" position to "tilt" position
moves the rod of bucket cylinder (4) toward the
machine front side.
As bar (3) moves a specific distance, proximity
switch (1) detects that it is away from the sens-
ing face, and returns the work equipment
(bucket) control lever to "hold" position.
Boom kick-out
q The boom kick-out is driven electrically. As the
lift arm is raised to an angle before reaching
the maximum height, the boom kick-out returns
the work equipment (lift arm) control lever from
the "raise" position to the "hold" position to
stop the lift arm automatically at a desired
height.
q Plate (6) is fixed to lift arm (5). And proximity
switch (2) is fixed to the front frame.
q Moving the work equipment (lift arm) control
lever from "lower" position to "raise" position
moves lift arm (5) upward.
As plate (6) moves a specific distance, proxim-
ity switch (2) detects that it is away from the
sensing face, and returns the work equipment
(lift arm) control lever to "hold" position.
WA320, 320PZ-6 10-700 11

700 Work equipment
Operation of proximity switch
When bucket is tilted
q While the bucket is dumped more than the q Shifting work equipment (bucket) control lever
position being set from the bucket positioner, (7) toward the tilt position moves spool (8) to
bar (2) moves on to the sensing face of prox- the position of the arrow. And spool is held
imity switch (1), turning on the proximity switch there by the energized coil of detent solenoid
(1) lamp. (6).
At this point, bucket positioner relay (4) is "ON" As a result, work equipment (bucket) control
and current flows to detent solenoid (6) of work lever (7) is held at "tilt" position and the bucket
equipment PPC valve (5) to energize the coil. tilts.
10-700 12 WA320, 320PZ-6

700 Work equipment
a The power supply for detent solenoid (6) oper-

ation is turned "ON" or "OFF" by alternator
relay (11).
Detent solenoid (6) circuit is turned off since L
signal from alternator (10) is not sent to alter-
nator relay (11) as long as the engine is
stopped.
As the result, the work equipment (bucket)
control lever (7) cannot be moved and held in
the tilt position as long as bar (2) is positioned
in sensing face of proximity switch (1).
Function of proximity switch
When object of sensing is over sensing face of

proximity switch
Lamp of proximity switch Turned ON
Bucket positioner relay ON

Work equipment PPC valve detent
Power ON
solenoid circuit
Energized
solenoid
When object of sensing is apart from sensing

face of proximity switch
Lamp of proximity switch Turned OFF
Bucket positioner relay OFF

Power OFF
solenoid circuit
De-energized
solenoid
q As the bucket is tilted and moved away from

the position set by the positioner, in other
words, as bar (2) moves away from the sens-
ing face of proximity switch (1), the lamp of
proximity switch (1) goes off and bucket posi-
tioner relay (4) is set to "OFF" state.
Because of above, detent solenoid (6) circuit
on work equipment PPC valve (5) is cut off and
the coil is de-energized.
Held bucket spool (8) receives the reaction
force of spring (9) and returns work equipment
(bucket) control lever (7) to "hold" position.
WA320, 320PZ-6 10-700 13

700 Work equipment
When lift arm is raised
q While lift arm (3) is dumped beyond the posi- q Shifting work equipment (lift arm) control lever
tion set from the boom kick-out, plate (2) (7) toward the raise position moves spool (8) to
moves on to the sensing face of proximity the position of the arrow. And spool is held
switch (1), turning on the proximity switch (1) there by the energized coil of detent solenoid
lamp. (6).
At this point, boom kick-out relay (4) is "ON" As a result, work equipment (lift arm) control
and current flows to detent solenoid (6) of work lever (7) is held at "raise" position and lift arm
equipment PPC valve (5) to energize the coil. (3) rises.
10-700 14 WA320, 320PZ-6

700 Work equipment

relay (11).
Detent solenoid (6) circuit is cut off since L sig-
nal from alternator (10) is not sent to alternator
relay (11) as long as the engine is stopped.
As the result, the work equipment (lift arm)
the raise position as long as plate (2) is posi-
tioned in sensing face of proximity switch (1).

proximity switch
Boom kick-out relay ON

Power ON
solenoid circuit
Energized
solenoid

Boom kick-out relay OFF

Power OFF
solenoid circuit
De-energized
solenoid
q As lift arm (3) is raised and moved away from

the position set by the boom kick-out, namely
as plate (2) moves away from the sensing face
of proximity switch (1), the lamp of proximity
switch (1) goes off and boom kick-out relay (4)
is set to "OFF" state.
Held lift arm spool (8) receives the reaction
(lift arm) control lever (7) to the "hold" position.
WA320, 320PZ-6 10-700 15

700 Work equipment
WA320PZ-6
1. Fork positioner proximity switch 5. Bucket cylinder

2. Bucket positioner proximity switch 6. Lift arm
3. Boom kick-out proximity switch 7. Plate
4. Bar
Unit: mm
Clearance on bucket positioner
8 proximity switch 35
Adjust
Clearance on boom kick-out
9 proximity switch 35
10-700 16 WA320, 320PZ-6

700 Work equipment
Outline
Bucket positioner or fork positioner

q The bucket positioner is driven electrically.
When the bucket or fork is returned to an angle
from the dump position to the tilt position, the
bucket positioner returns the work equipment
(bucket or fork) control lever from the "tilt" posi-
tion to the "hold" position to automatically stop
the bucket or fork at a proper digging angle or
lift angle.
q Bar (4) is fixed to the rod side of bucket cylin-
der (5). And proximity switches (1) and (2) are
fixed to the cylinder side.
q Moving the work equipment (bucket or fork)
control lever from "dump" position to "tilt" posi-
tion moves the rod of bucket cylinder (5)
toward the machine front side.
As bar (4) moves a specific distance, proximity
switches (1) and (2) detect that it is away from
the sensing face, and return the work equip-
ment (bucket or fork) control lever to "hold"
position.
q While the attachment selector switch of the
right-hand console is in the "BUCKET" posi-
tion, proximity switch (2) operates. While the
former is in the "FORK" position, proximity
switch (1) operates.
Boom kick-out
q The boom kick-out is driven electrically. As the
lift arm is raised to an angle before reaching
the maximum height, the boom kick-out returns
the work equipment (lift arm) control lever from
the "raise" position to the "hold" position to
stop the lift arm automatically at a desired
height.
q Plate (7) is fixed to lift arm (6). And proximity
switch (3) is fixed to the front frame.
q Moving the work equipment (lift arm) control
lever from "lower" position to "raise" position
moves lift arm (6) upward.
As plate (7) moves a specific distance, proxim-
ity switch (3) detects that it is away from the
sensing face, and returns the work equipment
(lift arm) control lever to "hold" position.
WA320, 320PZ-6 10-700 17

700 Work equipment
Operation of proximity switch
When bucket is tilted

a The case when the attachment selector switch is in the "BUCKET" position is shown below.
q While the bucket is dumped more than the q Shifting work equipment (bucket) control lever
position being set from the bucket positioner, (7) toward the tilt position moves spool (8) to
bar (2) moves on to the sensing face of prox- the position of the arrow. And spool is held
imity switch (1), turning on the proximity switch there by the energized coil of detent solenoid
(1) lamp. (6).
At this point, bucket positioner relay (4) is "ON" As a result, work equipment (bucket) control
and current flows to detent solenoid (6) of work lever (7) is held at "tilt" position and the bucket
equipment PPC valve (5) to energize the coil. tilts.
10-700 18 WA320, 320PZ-6

700 Work equipment

relay (11).
Detent solenoid (6) circuit is turned off since L
signal from alternator (10) is not sent to alter-
nator relay (11) as long as the engine is
stopped.
As the result, the work equipment (bucket)
the tilt position as long as bar (2) is positioned
in sensing face of proximity switch (1).

proximity switch
Bucket positioner relay ON

Power ON
solenoid circuit
Energized
solenoid

Bucket positioner relay OFF

Power OFF
solenoid circuit
De-energized
solenoid
q As the bucket is tilted and moved away from

the position set by the positioner, in other
words, as bar (2) moves away from the sens-
ing face of proximity switch (1), the lamp of
proximity switch (1) goes off and bucket posi-
tioner relay (4) is set to "OFF" state.
Held bucket spool (8) receives the reaction
(bucket) control lever (7) to "hold" position.
WA320, 320PZ-6 10-700 19

700 Work equipment
When lift arm is raised
q While lift arm (3) is dumped beyond the posi- q Shifting work equipment (lift arm) control lever
tion set from the boom kick-out, plate (2) (7) toward the raise position moves spool (8) to
moves on to the sensing face of proximity the position of the arrow. And spool is held
switch (1), turning on the proximity switch (1) there by the energized coil of detent solenoid
lamp. (6).
At this point, boom kick-out relay (4) is "ON" As a result, work equipment (lift arm) control
and current flows to detent solenoid (6) of work lever (7) is held at "raise" position and lift arm
equipment PPC valve (5) to energize the coil. (3) rises.
10-700 20 WA320, 320PZ-6

700 Work equipment

relay (11).
Detent solenoid (6) circuit is cut off since L sig-
nal from alternator (10) is not sent to alternator
relay (11) as long as the engine is stopped.
As the result, the work equipment (lift arm)
the raise position as long as plate (2) is posi-
tioned in sensing face of proximity switch (1).

proximity switch
Boom kick-out relay ON

Power ON
solenoid circuit
Energized
solenoid

Boom kick-out relay OFF

Power OFF
solenoid circuit
De-energized
solenoid
q As lift arm (3) is raised and moved away from

the position set by the boom kick-out, namely
as plate (2) moves away from the sensing face
of proximity switch (1), the lamp of proximity
switch (1) lamp goes off and boom kick-out
relay (4) is set to "OFF" state.
Held lift arm spool (8) receives the reaction
(lift arm) control lever (7) to the "hold" position.
WA320, 320PZ-6 10-700 21

700 Work equipment
SEN04180-02 Work equipment cylinder
Work equipment cylinder 1
WA320-6
Lift cylinder
Bucket cylinder
Unit: mm
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
Clearance between 0.030 +0.279 0.095
1 piston rod and bushing Lift 75 0.655 Replace bushing
0.076 +0.065 0.355
0.030 +0.258 0.078
Bucket 80 0.634
0.076 +0.048 0.334
10-700 22 WA320, 320PZ-6

700 Work equipment
Work equipment cylinder SEN04180-02
WA320PZ-6
Lift cylinder
Bucket cylinder
Unit: mm
Cylinder Standard Tolerance Standard Clearance
name size Shaft Hole clearance limit
Clearance between 0.030 +0.279 0.095
1 piston rod and bushing Lift 75 0.655 Replace bushing
0.076 +0.065 0.355
0.036 +0.261 0.083
Bucket 110 0.651
0.090 +0.047 0.351
WA320, 320PZ-6 10-700 23

SEN04180-02

2009 KOMATSU
All Rights Reserved
10-700 24
SEN04181-00
WA320-6
WA320PZ-6
WA320-6 70001 and up


800 Cab and its attachments

Cab ................................................................................................................................................................. 3
Air conditioner ................................................................................................................................................. 4
WA320, 320PZ-6 10-800 1

SEN04181-00
10-800 2 WA320, 320PZ-6

Cab SEN04181-00
Cab 1
1. Front working lamp

2. Radio antenna
3. Door (left)
4. Air conditioner external air filter
5. Front glass
6. Front wiper
7. KOMTRAX GPS antenna
(WA320-6: if equipped)
(WA320PZ-6: standard)
8. KOMTRAX communication antenna
9. Door (right)
10. Rear wiper
WA320, 320PZ-6 10-800 3

SEN04181-00 Air conditioner
Air conditioner 1
Air conditioner piping diagram 1
10-800 4 WA320, 320PZ-6

Air conditioner SEN04181-00
1. Hot water take-out piping Specifications

2. Compressor Refrigerant used R134a
3. Condenser
4. Receiver Refrigerant refilling level (g) 900
5. Hot water return piping
6. Refrigerant piping
7. External air filter
8. Internal/external air changeover damper
9. Blower unit
10. Air conditioner unit
11. Dual pressure switch
12. Air outlet duct
13. Cool and hot box (if equipped)
14. Internal air filter
WA320, 320PZ-6 10-800 5

Refrigerant circuit diagram
1. Engine
2. Compressor
3. Condenser
4. Receiver
5. Air conditioner unit
6. Dual pressure switch
Table of tightening torque for refrigerant piping adapter

Unit: Nm {kgm}
12 15 {1.2 1.5}
7 Air conditioner unit refrigerant inlet side
(screw size: M16 x 1.5)
30 35 {3.1 3.6}
8 Air conditioner unit refrigerant outlet side (screw size: M24 x 1.5)
8 12 {0.8 1.2}
9 Receiver refrigerant pipe set bolt
(screw size: M16 x 1.0)
Retighten
20 25 {2.0 2.6}
10 Compressor refrigerant piping lock bolt (screw size: M8 x 1.25)
20 25 {2.0 2.6}
11 Condenser refrigerant inlet side (screw size: M22 x 1.5)
12 15 {1.2 1.5}
12 Condenser refrigerant outlet side (screw size: M16 x 1.5)
10-800 6 WA320, 320PZ-6

Air conditioner unit 1
A: From receiver Outline

B: To compressor q The vertical air conditioner unit on which evap-
C: Hot water inlet orator (1) and heater core (2) is synchronized
D: Hot water outlet with the blower and intake unit to generate cool
and hot air.
1. Evaporator q The temperature adjusting switch on the air
2. Heater core conditioner panel controls air mix dampers (3)
3. Air mix damper (upper) and (4) to adjust the spurting out temperature.
4. Air mix damper (lower)
5. Expansion valve Cooler
6. Blower controller q The cooler circulates refrigerant through evap-
7. Blower motor relay orator (1) to cause heat exchange (dehumidifi-
8. Compressor clutch relay cation and cooling).
9. Air mix damper actuator q Air taken in by the blower and intake unit is
10. Evaporator temperature sensor cooled with evaporator (1) and then blown out
11. Dual pressure switch from the duct and grill.
Heater
q The heater circulates engine coolant in heater
core (2) to cause heat exchange (heating).
q Air taken in by the blower and intake unit is
heated with heater core (2) and then blown out
through the duct and grill.
WA320, 320PZ-6 10-800 7

Functions of major components

Evaporator Air mix damper actuator
q Evaporator fin is cooled by the low-pressure, q It starts the built-in motor receiving signal cur-
low-temperature refrigerant gas being sent rent from the air conditioner panel in order to
from the expansion valve. Air from the blower open or close the air mix damper through the
motor is cooled and dehumidified when pass- link mechanism.
ing through the fin. q The motor rotating direction is determined as
the air conditioner panel reads the position of
Heater core the potentiometer being built in the actuator.
q Fin of the heater core is heated by the hot This reading is done as the target temperature
water (cooling water) being sent from the is set from the temperature adjustment switch
engine. Air from the blower motor is heated as on the air conditioner panel.
it passes through the fin. q Rotation of the motor is stopped as the con-
tact, which is to move interlocked with the
Expansion valve motor, moves away or signal current from the
q This valve converts high-pressure, high-tem- air conditioner panel is turned "OFF".
perature liquid refrigerant from the receiver to
low-pressure, low-temperature misty refriger- Evaporator temperature sensor
ant through the throttling function. q In order to prevent freezing of the evaporator, it
It controls flow rate of refrigerant by changing senses the evaporator temperature and sends
level of throttling depending on the thermal necessary signals to the air conditioner panel.
load in the operator's cab. The signal sent to the air conditioner panel is
used to control the compressor. As the result,
Blower controller temperature of the air blown out of the grill is
q It controls the blower motor speed receiving adjusted depending on the volume of refriger-
signal current from the air conditioner panel. ant circulated in the evaporator.
Blower motor relay Dual pressure switch

q Signal current from the air conditioner panel q If abnormally low or high pressure was gener-
controls the relay coil. As the relay coil is ener- ated in the refrigerant circulation circuit, this
gized and the switch is turned "ON", power is switch releases the magnet clutch of the com-
supplied to the blower motor. pressor to protect a series of cooler-related
equipment.
Compressor clutch relay
q Signal current from the air conditioner panel
dual pressure switch is used for controlling the
relay coil. As the relay coil is energized and the
switch is turned "ON", the magnet clutch of the
compressor is connected.
LA: 0.20 MPa {2 kg/cm2}

LB: 0.02 MPa {0.2 kg/cm2}
HA: 3.14 MPa {32 kg/cm2}
HB: 0.59 MPa {6 kg/cm2}
10-800 8 WA320, 320PZ-6

Blower and intake unit 1
1. Blower motor assembly Functions of major components

2. Internal/external air changeover damper actuator Blower motor assembly
3. Internal/external air changeover damper
q It suctions air by rotating the fin installed on the
blower motor. And it is also used for sending
the absorbed air to the evaporator and heater
core.
Internal/external air changeover damper actuator

q Receiving signal current from the air condi-
tioner panel, it starts the built-in motor to open
or close the internal/external air changeover
damper through the link mechanism.
q The motor rotation direction is determined from
the internal/external air changeover switch on
the air conditioner panel.
q Rotation of the motor is stopped as the con-
tact, which is to move interlocked with the
motor, moves away or signal current from the
air conditioner panel is turned "OFF".
WA320, 320PZ-6 10-800 9

Compressor 1
A: From air conditioner unit Function

B: To condenser q Other than circulating the refrigerant, it com-
presses the refrigerant gas from the evapora-
tor to high-pressure, high-temperature misty
refrigerant so that it may be easily regenerated
(liquefied) at normal temperature.
q Its built-in magnet clutch turns on or off
depending on the evaporator temperature and
refrigerant pressure.
Specifications
Number of cylinders
7 29.3 x 27.4
Bore x Stroke (mm)
Piston capacity (cc/rev) 129.2
Allowable maximum speed
4,000
(rpm)
Refrigerant oil used Sanden: SP-10
Refrigerant oil refilling volume
135
(cc)
10-800 10 WA320, 320PZ-6

Condenser 1
A: From compressor Function

B: To receiver q It cools and liquefies the high-pressure and
high-temperature misty refrigerant from the
compressor.
a If the fin crushes or is clogged with dusts, heat

exchange efficiency is degraded and complete
liquefaction of refrigerant becomes unavail-
able. As the result, pressure in the refrigerant
circulation circuit will be increased, applying
extra load to the engine or degrading the cool-
ing effect. Thus, care must be used in its han-
dling and daily inspection.
Specifications
Fin pitch (mm) 1.5
Total heat dissipation area (m2) 6.55

Max. pressure used
3.6 {36}
(MPa {kg/cm2})
WA320, 320PZ-6 10-800 11

Receiver 1
A: From condenser Function

B: To air conditioner unit q It is used to store liquefied high-pressure, high-
temperature misty refrigerant from the con-
1. Sight glass denser. It is capable of completely liquefying
the refrigerant even when bubbles are con-
tained in the refrigerant due to the condenser
condition in heat dissipation.
q It eliminates foreign substances in the circula-
tion circuit and water content in the refrigerant
by use of the built-in filter and desiccating
agent.
q Sight glass (1) allows inspecting flow of the
refrigerant.
Specifications
Effective cubic capacity (cm3) 578
Weight of desiccating agent (g) 300
10-800 12 WA320, 320PZ-6

WA320, 320PZ-6 10-800 13

Air conditioner panel 1
Display unit
Display Display
No. Display items Display range Display method Remarks
category color
Spurting out See above All segments below applicable level come
1
temperature drawing on (8-step display)
Gauge
Air blasting See above All segments below applicable level come
2
volume drawing on (4-step display)
The display indicates which is currently
Circulation of When circulating Liquid
taking place - internal air circulation or Black
internal air and internal air and crystal
3 external air introduction - responding to the
introduction of introducing
operation of the internal/external air
Pilot external air external air
changeover switch.
When air
Turns "ON" air conditioner switch, this lamp
4 Air conditioner conditioner switch
lights up.
is "ON"
Switch block
No. Switch name Function Operation
Circulation of
This switch is used to select either the circulation of internal air or
internal air
Internal/external air introduction of external air
5 IO
changeover switch (pilot display on the display unit is switched depending on the switch
Introduction of
setting)
external air
6 Air conditioner switch It turns on or off the cooling and the dehumidifying heating function. OFF io ON
It turns on or off main power supply of the air conditioner.
7 Main power switch ON: Settings done during "OFF" are indicated on the display unit. OFF io ON
OFF: Turns off the display unit lamp and stops the fan.
It controls volume of air sent from the fan.
8 Fan switch LO io HI
(adjusted in 4 steps [LO, M1, M2 and HI])
Low temperature
Temperature adjusting It controls the spurting out temperature
9 IO
switch (8-step adjustment)
High temperature
10-800 14 WA320, 320PZ-6

Outline
q CPU (central processing unit) installed on the
panel processes input signals from respective
sensors and operation signals of the panel
switches to display and output them.
q The self-diagnosis function of CPU makes the
troubleshooting easier.
Input and output signals

JAE IL-AG5-14P [CN-C48] JAE IL-AG5-22P [CN-C47]
Input and Input and
Pin No. Signal name output Pin No. Signal name output
signals signals
1 GND 1 NC
2 Sensor ground 2 NC
Internal/external air changeover damper 3 Blower motor relay Input
3 Input
actuator limiter Internal/external air changeover damper
4 Output
4 External air temperature sensor Input actuator output 1
5 Evaporator temperature sensor Input Internal/external air changeover damper
5 Output
6 Internal air temperature sensor Input actuator output 2
7 Starting switch (ON) Input 6 Mode selector actuator output 2 Output
8 Night lamp signal Input 7 Mode selector actuator output 1 Output
9 NC 8 Air mix damper actuator output 2 Output
10 NC 9 Air mix damper actuator output 1 Output
11 NC Actuator potentiometer power supply
10
(5 V)
12 NC
11 NC
13 Day light sensor 2 Input
12 NC
14 Day light sensor 1 Output
13 NC
14 NC
15 Magnet clutch Input
16 Air mix damper actuator limiter Input
17 Mode selector actuator limiter Input
18 Air mix damper actuator potentiometer Input
19 Mode selector actuator potentiometer Input
20 Blower gate Input
21 Blower feedback Input
22 Actuator potentiometer ground
WA320, 320PZ-6 10-800 15

SEN04181-00

2008 KOMATSU
All Rights Reserved
10-800 16
SEN04182-02
WA320-6
WA320PZ-6
WA320-6 70001 and up


910 Electrical system, Part 1

Machine monitor system ................................................................................................................................. 2
Machine monitor ............................................................................................................................................. 6
WA320, 320PZ-6 10-910 1

SEN04182-02 Machine monitor system
Machine monitor system 1
Outline
q In the machine monitor system, each controller 4. In addition to the above, the following display,
on the network monitors controls the machine setting and adjustment functions are provided
condition with the sensors installed to various using the character display and the machine
parts of the machine, and then sends the result monitor mode selector switch, which is the
as network information to the machine monitor, operation switch of the character display.
which displays the information to notify the 1) Switching of traction level
operator of the machine condition. 2) Switching of HST reverse travel gear shift-
ing pattern
q The machine monitor displays the information 3) Display the odometer
in the operator mode or service mode. 4) Resetting the filter or oil replacement time
5) Input the telephone number
q The operator mode is used to display the infor- 6) Selecting the language
mation to the operator normally. The major 7) Adjusting the illuminance of nighttime light
functions used in the service mode are as fol- 8) Travel speed/engine speed display select-
lows. ing function
9) Function for setting display/no-display of
1. Items always displayed travel speed or engine speed to the char-
q Meters (speedometer or engine tachome- acter display
ter)
q Gauges (engine coolant temperature
gauge, HST oil temperature gauge and
fuel gauge)
q Pilot indicators
q Service meter
The following items are displayed according to

the set state of the optional device selecting
function.
q Travel speed or engine speed indication
on the character display
2. Items displayed when abnormality is detected

q Caution lamps
q Action code (while an action code is dis-
played, if the machine monitor mode
selector switch (>) is pressed and
released, the failure code (6 digits) is dis-
played.)
3. At the replacement period of a filter or oil, the

character display displays that filter or oil.
(maintenance monitoring function)
10-910 2 WA320, 320PZ-6

Machine monitor system SEN04182-02
q The service mode function is provided for the 10. Machine serial number input function
ease of troubleshooting for the controllers on Enters the machine serial number to identify
the network (including the machine monitor the machine.
itself). The major functions used in this mode
are as follows. 11. Model selection function
Enters the information of applicable model.
1. Electrical system failure history display func-
tion 12. Initialize function
The electrical system failures of each controller Sets the machine monitor to the state set when
saved in the machine monitor are displayed. the machine is delivered.
The information of those failures is also
deleted with this function.
2. Mechanical system failure history display func-

tion
The mechanical system failures of each con-
troller saved in the machine monitor are dis-
played.
3. Real-time monitoring function

The input and output signals recognized by
each controller on the network are displayed in
real time.
4. Engine reduced-cylinder function

This function is used for the purpose of speci-
fying cylinder having defective combustion by
stopping fuel injection to each cylinder from the
fuel injector.
5. No injection cranking function

Before restarting engine after a long-term stor-
ing of the machine, this function is used to
lubricate the engine internally.
6. Adjustment function
Functions are provided to correct and adjust
the installation errors and manufacturing dis-
persion of the sensors, solenoid valves, etc.
Function for changing control characteristics is
provided on user request.
7. Maintenance monitoring function

Changes the filter or oil replacement time and
makes ON/OFF selection of the function.
8. Operating information display function

Displays fuel consumption per operating hour.
9. Optional device selecting function

Verifies the installation of optional devices or
changes their setting.
WA320, 320PZ-6 10-910 3

SEN04182-02 Machine monitor system
System circuit diagram

a Items marked with "*1" in drawing may or may not installed.
10-910 4 WA320, 320PZ-6

Machine monitor system SEN04182-02
WA320, 320PZ-6 10-910 5

SEN04182-02 Machine monitor
Machine monitor 1
1. HST oil temperature gauge 21. Quick coupler operation pilot lamp (*2)
2. HST oil temperature caution lamp 22. Cooling fan reverse rotation pilot lamp
3. Engine coolant temperature gauge 23. Maintenance caution lamp
4. Engine coolant temperature caution lamp 24. Parking brake reminder caution lamp
5. Speedometer or engine tachometer 25. Battery charge circuit caution lamp
6. Turn signal pilot lamp (left) 26. Steering oil pressure caution lamp (*2)
7. Head lamp high beam pilot lamp 27. Emergency steering pilot lamp (*2)
8. Turn signal pilot lamp (right) 28. Meter display pilot lamp
9. Fuel level caution lamp 29. Character display portion
10. Fuel gauge 30. Preheating pilot lamp
11. Central warning lamp 31. Directional selector switch actuation pilot lamp
12. Brake oil pressure caution lamp (*2)
13. Engine oil pressure caution lamp 32. Economy operation display lamp
14. Water separator caution lamp 33. Shift hold pilot lamp (*1)
15. Engine oil level caution lamp 34. S mode operation pilot lamp
16. Radiator coolant level caution lamp 35. Traction control operation pilot lamp
17. HST oil filter clogging caution lamp 36. Travel speed range selector switch position
18. Air cleaner clogging caution lamp pilot lamp
19. Parking brake pilot lamp 37. Directional lever position pilot lamp
20. Brake oil temperature caution lamp
*1: Not used by this model

*2: If equipped
10-910 6 WA320, 320PZ-6

Machine monitor SEN04182-02
List of items displayed on monitor 1
Condition for judging that the engine is running:

If 2 or more are met in the following 3 conditions, the engine is judged running when the abnormality in the
CAN communication occurs and the charge level exceeds the specified level.
1. Turning "ON" of the starting switch is recorded (IGN-C signal was entered)
2. Charge level exceeds the specified value (the voltage reached 12 V once and remains 5 V or above after
that)
3. Engine speed is 500 rpm or above
Lamp Lamp period Alarm buzzer Operating condition Buzzer period Priority
Warning for dangerous Period: 1,600 msec.
w: Intermittent
Q: ON sounds condition (error or caution ON: 800 msec. 1
message is generated) OFF: 800 msec. (duty 50%)
Period: 1,600 msec. Caution for erroneous Period: 240 msec.
A: Intermittent
w: Flashing ON: 800 msec. sounds operation (when an irregular ON: 80 msec. 2
OFF: 800 msec. (duty 50%) operation is done) OFF: 160 msec.
Period: 240 msec.
E: Canceling Set cancellation such as
A: Intermittent ON: 80 msec.
calibration (inoperative state) ON: 1,000 msec. (1 time)
3
sounds
OFF: 160 msec.
Completion of setting such ON: 100 msec.
E: Separately e: Completion
as calibration (when normally OFF: 160 msec. 4
set conditions sounds
ended) ON: 100 msec. (1 time)
Detecting Operating condition

time
(sec) Engine stopped Engine is running
Display color
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Category No. Item Device Operating condition Remarks
Display of
Display of
Detection
message
message
Reset
lamp
lamp
Turned ON with errors (E03
and E02) of each controller,
When error occurs E E E E E E E E simultaneously displaying the
message on the character
Central Central
Red
11 LED display.
warning lamp warning
For other than above, see
"Operating condition, central

warning lamp" of other
items.
White
When lamp switch is other
Back light Back light LED
than "OFF"
White range: 30 105C

Other than below
Red range: 105 135C
Pointer:
Movement When the sensor is
1 HST oil
Red
Alarm: 105C or above 10 1 w Q Q B@CRNS w Q Q B@CRNS disconnected or hot short-

2 temperature
Caution circuited: Max
lamp: LED When abnormality is When sensor was
detected (out of input signal 20 5 DGH1KX DGH1KX disconnected or hot short-
range) circuited: Min
Other than below
White range: 50 102C

Alarm: 102C or above 3 0 Q Q Red range: 102 135C
Gauges and Pointer:
meters Movement When the sensor is
3 Engine coolant
Red
Alarm: 105C or above w Q Q B@BCNS w Q Q B@BCNS disconnected or hot short-

4 temperature
Caution circuited: Max
lamp: LED When sensor was
When abnormality is disconnected or hot short-
CA144 CA144
detected (high temperature) circuited: Min
When abnormality is
CA145 CA145
detected (low temperature)
When engine speed display (selectable with the machine

Engine speed monitor setting)
is selected
Pointer:
5
Movement When a communication error is
When travel speed display is detected, the system displays
Travel speed
selected "0".
Other than below Max: 10 z

Min: 85 z
Pointer:
Movement Min. 80 z 10 1 Q Q
Gauges and 9 When the sensor is grounded:
Red
Fuel level
meters 10 Full
Caution
When abnormality is When sensor was
lamp: LED
detected (input voltage is 4 disconnected or hot short-
10 2 DJF1KA DJF1KA circuited: Empty
V or above and no incoming
IGN-C signal is detected)
WA320, 320PZ-6 10-910 7


time
Display color
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Display of
Display of
Detection
message
message
Reset
lamp
lamp
Operates when charging
Service meter normally at 1 : 1 to the clock
Displays various codes and
Black
Character time
29 LCD items according to the machine
display
Converts travel speed pulse condition and switch operation.
Odometer
into travel distance
x 100 r/min
Green
When engine speed display (setting of a desired value is
Engine speed 0 0 Q Q
is selected available from the machine
monitor)
Unit 28 LED
km/h or MPH
Green
When travel speed display is (setting of a desired value is
Travel speed 0 0 Q Q
selected available from the machine
monitor)
When F is selected (neutral
Green Green Green Green Green Green Orange Green

F LED safety is displayed as engine 1 0 A Q Q Q
is stopped)
Directional
37 lever N LED When N is selected 0 0 Q Q
position
When R is selected (neutral
R LED safety is displayed as engine 1 0 A Q Q Q
is stopped)
When error occurs in
Items related
When 4th gear speed is communication, condition is
to gear 4 LED 0 0 Q Q
selected held until starting switch is
shifting
turned "OFF".
Travel When 3rd gear speed is
speed 3 LED 0 0 Q Q
selected
range
36
selector
When 2nd gear speed is
switch 2 LED 0 0 Q Q
position selected
When 1st gear speed is

1 LED 0 0 Q Q
selected
When turn signal lever and

6 Hazard lamp operates when
Turn signal LED hazard lamp switch signal is 0 0 Q Q
8 starting switch is turned "OFF".
input
When head lamp is set to
Blue
Head lamp high beam (when head lamp

7 LED 0 0 Q Q
high beam is "ON" and dimmer switch
is "ON")
Normal oil pressure

(CLOSE)
Below set pressure (OPEN)

(detection time continues)
1 1 Q w Q Q
Brake oil and 30 seconds after engine
Red
12 LED is started (no detection time)

pressure
Below set pressure (OPEN)
(detect time continues) and
after 30 seconds elapsed 5 1 w Q Q 2G40ZG
since engine was started (no
detection time)
Normal oil pressure

(CLOSE)
Other Engine oil
Red
symbols 13 LED
pressure
Low oil pressure (OPEN) w Q Q B@BAZG w Q Q B@BAZG
Normal
Water
Red
14 LED
separator
Water mixing with fuel Q CA418 Q CA418
If low level is detected when

Normal oil level (CLOSE) starting switch is turned "ON",
alarm is continued even after
Red
15 Engine oil level LED engine is started until adequate

oil level is reached. Don't check
Low oil level (OPEN) 2 1 Q B@BAZK the oil level for 300 sec, after
stopping the engine.
Normal coolant level

(CLOSE)
Radiator
Red
16 LED
coolant level
Low coolant level (OPEN) 30 1 Q B@BCZK Q B@BCZK
10-910 8 WA320, 320PZ-6


time
Display color
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Display of
Display of
Detection
message
message
Reset
lamp
lamp
Normal (OPEN)
Clogging (CLOSE) (HST oil

temperature 50C or above
HST oil filter 10 2 Q 6091NX
Red
17 LED and no abnormality
clogging detected)
When abnormality is
detected (clogging was KEY
3 DHTCL6 DHTCL6
detected as engine was OFF
stopped)
Normal (OPEN)
Air cleaner
Red
18 LED
clogging
Clogging (GND) 2 1 Q AA1ANX
Operation (OPEN) Q Q
Released (CLOSE)
Red
19 Parking brake LED
Engine is running, parking

brake operated and the
0 0 A Q Q
directional lever is at any
position other than "N"
Other than below
Temperature rise (oil

temperature: Min. 120C 5 5 Q Q
(alarm)
Temperature rise (1. or 2.)
1. Oil temperature 130C or To be released if the oil
Brake oil above temperature is detected
Red
20 LED 5 5 w Q Q B@C6NS w Q Q B@C6NS
temperature 2. Oil temperature 125C or consecutively at lower than
above and travel speed 125C for 5 sec.
Other 35 km/h or above
symbols
When abnormality is
DGR2KB DGR2KB
detected (ground fault)
When abnormality is
detected (disconnection or DGR2KZ DGR2KZ
hot short-circuit)
Alarm buzzer is sounded when
Other than below connection of quick coupler is
Quick coupler reset. Error message is
Red
21 LED
operation simultaneously displayed on
When quick coupler is
0 0 A Q Remarks A Q Remarks the character display.
disconnected "PIN DISCONNECT"
Normal 0 0
Error message is displayed on
Orange
Cooling fan the character display as long

22 reverse LED Reverse 0 0 Q Remarks Q Remarks as reverse rotation of fan is
rotation continued.
"COOLING FAN REVERSE"
Selecting reverse rotation 0 0 w w
Ordinary
Message is simultaneously
Red
23 Maintenance LED displayed on the character

30 hours or less before display.
maintenance or Q E Q E
maintenance time
Error message is displayed on
Other than below the character display as long
as parking brake is left
unapplied.
The alarm continues as long as
Parking brake starting switch is turned "OFF".
Red
24 LED
reminder This function can be enabled
When parking brake is left
0 0 w Q Q Remarks when "MECHA" is selected for
unapplied (CLOSE) "7: PKG BRAKE" from the
"Option device selecting
function" of the machine
monitor.
WA320, 320PZ-6 10-910 9


time
Display color
Individual display
Individual display
Central warning
Central warning
Alarm buzzer
Alarm buzzer
Display of
Display of
Detection
message
message
Reset
lamp
lamp
Normal voltage If abnormality is detected when
starting switch is turned "ON",
alarm is continued even after
Engine is running, alternator engine is started.
Battery charge voltage is below the
Red
25 LED 30 1 w Q Q AB00MA
circuit specified level, and no <Voltage hysteresis>
incoming ING-C is present. Judgement for Abnormal o
Normal: 12 V or above
When abnormality is
Judgement for Normal o
detected (unmatched engine 3 1 w Q Q AB00L6
Abnormal: 5 V or below
condition and the signal)
This function can be enabled

Oil pressure normal (OPEN) when "ADD" is selected for
"2: EMERG S/T" from the
"Optional device selecting
Steering oil
Red
26 LED 0.5 0 Q Q function" of the machine
pressure
monitor.
Low oil pressure (CLOSE) *: The function is reset
(*) immediately when engine is
3 w Q DDS5L6
1 stopped.

Oil pressure normal (OPEN) 0 0 Q Q when "ADD" is selected for
Green
Emergency "2: EMERG S/T" from the
27 LED
steering "Optional device selecting
Low oil pressure (CLOSE) function" of the machine
monitor.
Other than below
Red
30 Preheating LED
When preheater is turned on 0 0 Q Q
Other
symbols
When directional lever is

used
When directional selector when "ADD" is selected for
0 0 Q Q
Directional switch is used "3: FNR" from the "Optional
31 selector switch LED Green device selecting function" of
actuation Directional lever priority the machine monitor.
0 0 A w Q A w Q Not to be displayed when error
caution
is made in communication.
Directional selector switch
0 0 A w Q A w Q
neutral caution
Other than below 0 0

Green
Economy
32 LED
operation
Economy mode operation 0 0 Q Q
Other than below

Green
S mode
34 LED The lamp goes off when
operation
S mode operation is traction control is reset from
0 0 Q Q
selected max. traction switch. When
traction control is reset with
max. traction switch, the lamp
Other than below is lit again when directional
Traction
Green
35 control LED lever position is switched.

operation Traction control operation is
0 0 Q Q
turned on
10-910 10 WA320, 320PZ-6

Machine monitor operation switch 1
1. Machine monitor mode selector switch 1

2. Machine monitor mode selector switch 2
WA320, 320PZ-6 10-910 11

Setting of machine monitor 1
1. Spare rotary switch (SW1)

4. Spare dip switch (SW5-1)
a It is prohibited to change setting of spare rotary switch and DIP switch.
Troubleshooting function 1
q The machine monitor monitors the input and output signals constantly for troubleshooting for the sys-
tem.
q If each controller detects abnormality by the self-diagnosis, abnormality information is forwarded to the
machine monitor over the network.
q Abnormality information can be checked on the character display using the failure code display mode of
the machine monitor.
10-910 12 WA320, 320PZ-6

Character display function 1

q Machine monitor display and setting can be changed by using the character display.
q The range where operator is enabled to operate is within the portion of the "Operator mode" in the figure
below.
a For the operating method in the operator mode, see the Operation and maintenance manual.
*1: When an ID entered from the "ID entry" screen is once approved, display changes directly to the "Select
function" screen without displaying the "ID entry" screen until the starting switch is turned "OFF".
WA320, 320PZ-6 10-910 13

Operator mode functions 1

Self-check screen (0th layer)
q Self-check is conducted for 3 seconds automatically when starting switch is turned to "ON".
q During a self-check, entry through the machine monitor operating switch is not accepted.
q After ending the self-check, the self-check screen automatically moves to 1st layer.
Normal screen (1st layer)

q If the item of "13: RPM/SPEED" is set to "ADD" in the "Optional device selecting function" of machine
monitor and the menu of "Engine speed display / non-display setting" is set to "rpm OFFoON" in the
"Display of functions opened to the operator", engine speed is displayed to the character display when
the travel speed is displayed at the center of the monitor.
q When the engine speed is displayed at the center of the monitor, travel speed is displayed to the charac-
ter display.
q Pressing the "U" switch changes the screen to the 2nd layer.
1. Engine speed display

2. Travel speed display
A. In the case of "km/h" display
B. In the case "MPH" display
a When "SI unit specification" is selected for the "Factory mode" from the machine monitor, the character
display shows the engine speed in "rpm" and the monitor center display is fixed to the travel speed in
"km/h".
10-910 14 WA320, 320PZ-6

Failure code screen (1st layer)

q Pressing the ">" switch while the Warning screen is on display changes display to the Failure code
screen.
q If multiple failure codes are present, pressing of the ">" switch sequentially displays them from the item
of higher priority downward. If items have the same priority, the item that occurred most recently will be
displayed first.
Example of a failure code screen (simultaneously occurring errors: DX16KA, B@BCZK and CA431)
*1: The screen automatically returns to the Warning screen if the switch is not pressed more than 10 sec-
onds in the Normal screen display.
*2: The screen returns to the Warning screen if the switch is not pressed more than 30 seconds in the fail-
ure code screen or if a new alarm is turned ON.
*3: Pressing the ">" switch on the Normal screen before 10 seconds lapse changes display to the initial fail-
ure code screen.
WA320, 320PZ-6 10-910 15

Display of functions opened to the operator (2nd layer or below)

q Certain menus are not displayed unless the items in the "Optional device selecting function" of the
machine monitor are set.
q Pressing "U" switch allows selecting each menu.
q For the 2nd layer down, the screen automatically returns to the screen of the 1st layer if the switch is not
pressed more than 60 seconds in the screen display of each menu.
q The language will be displayed as set in the Language selection function.
a See the "Operation and maintenance manual" for details of each menu.
*1: These menus are displayed when "ADD" is selected for "13: RPM/SPEED" item from the "Optional
device selecting function" of the machine monitor.
*2: These menus are displayed when "ADD" is selected for "12: RPM/OPT" item from the "Optional device
selecting function" of the machine monitor.
k It is prohibited to select "ADD" for "12: RPM/OPT" from the "Optional device selecting function"
of the machine monitor in the regions where the applicable law requires to display the travel
speed.
10-910 16 WA320, 320PZ-6

Service mode functions 1

q The machine monitor is provided with service mode function for the ease of troubleshooting for the con-
trollers on the network (including the machine monitor itself).
q Initial setting of the sensors and optional setting can be made in the service mode of the machine moni-
tor.
Procedure for switching to Service Mode

1. Checking of the screen display 3. ID input and confirmation
Check that the character display is set to the Operate the machine monitor mode selector
1st layer screen in the operator mode. switches 1 and 2 and enter ID. (ID: 6491)
2. Display of ID input initial screen

Pressing "u" switch and "<" switch simulta-
neously for 5 seconds or more displays the ID
entry initial screen.
a Pressing down the 2 switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the switches.
1) The cursor (C) is located at the highest-

order digit. Pressing "<" or ">" switch
changes the value of this digit in the range
of "0" to "9".
2) Press "U" switch at the target value to
validate it.
a The cursor moves to the 2nd digit
position.
3) Confirm the values for the 2nd digit and
onward following the same procedure.
a If you have entered a wrong value to
a p os it io n whe n the c ur s or was
located at any position other than the
highest-order digit, press "t" switch
to move the cursor to the highest-
order digit to enable to input correct
value. In this case, the values already
entered remain on the screen
unchanged.
a Pressing "t" switch when the cursor
is located at the highest-order digit,
the screen returns to the "1st layer" of
the operator mode.
a If switch is not operated more than 60
seconds on the "ID entry" screen, it
automatically returns to the "1st layer"
screen of the operator mode.
4) If ID is acknowledged upon confirming the
4th digit, the screen changes to the "Elec-
trical system failure history" selector
screen.
WA320, 320PZ-6 10-910 17

Service mode menu
a Pressing "<" or ">" switch on the menu screen switches individual menus of the service mode sequen-
tially and endlessly.
a Pressing "U" switch on the target menu screen changes the screen to the detailed screen of the same
menu.
a Pressing "t" switch on the menu screen returns the screen to the 1st layer of the operator mode.
10-910 18 WA320, 320PZ-6

Electrical system failure history display Real-time monitoring function (REAL-TIME

function (ELECTRIC FAULT) MONITOR)
a "**" field displays total number of the failure q This function is used to check on the input/out-
history currently recorded. (max. 20 histories to put signals, etc. each controller on the network
be stored) recognizes.
a For the operating procedure of this function,
q The history is used to check on the electrical see "Special functions of machine monitor
system failures of each controller saved in the (EMMS)" in Testing and adjusting.
machine monitor. After repairing the failure
content and verifying normal function, the fail-
ure history may be erased.
see "Special functions of machine monitor
(EMMS)" in Testing and adjusting.
Mechanical system failure history display Engine reduced-cylinder function (CYLINDER

function (MACHINE FAULT) CUT-OUT)
a "**" field displays total number of the failure q This function is used for the purpose of speci-
history currently recorded. (max. 20 histories to fying cylinder having defective combustion by
be stored) stopping fuel injection to each cylinder from the
q The history is used to check on the mechanical fuel injector.
system failures of each controller saved in the a For the operating procedure of this function,
machine monitor. see "Special functions of machine monitor
a For the operating procedure of this function, (EMMS)" in Testing and adjusting.
WA320, 320PZ-6 10-910 19

No injection cranking function (NO INJECTION) Maintenance monitoring function (MAINTE-

NANCE MONITOR)
q Before restarting engine after a long-term stor-

ing of the machine, this function is used to q This function is used for changing the filter and
lubricate the engine internally. oil replacement timing and making ON/OFF
a For the operating procedure of this function, selection of this function.
see "Special functions of machine monitor a For the operating procedure of this function,
(EMMS)" in Testing and adjusting. see "Special functions of machine monitor
Adjustment function (TUNING) Operating information display function (OPER-

ATION INFO)
q This function is used for correcting and adjust-

ing the installation errors and manufacturing q This function is used for displaying fuel con-
dispersion of the sensors, solenoid valves, etc. sumption per operating hour.
Function for changing control characteristics is a For the operating procedure of this function,
provided on user request. see "Special functions of machine monitor
These functions are also used when sensors, (EMMS)" in Testing and adjusting.
valves and controllers are replaced or added.
10-910 20 WA320, 320PZ-6

Optional device selecting function (OPTIONAL Model selection function (MACHINE)

SELECT)
q This function is used for displaying or changing

q This function is used for verifying the installed the setting of model information (machine
state of optional devices or when changing name).
their setting. a For the operating procedure of this function,
This function is also used for installing or see "Special functions of machine monitor
removing optional devices. (EMMS)" in Testing and adjusting.
a For the operating procedure of this function, a The figure shows when "WA250" is selected.
Machine serial number input function Initialize function (INITIALIZE)

(MACHINE No. SET)
q This function is used to set the machine moni-

q This function is used for displaying or entering tor to the state set when delivered.
the serial number of machine. a Since this function is specially handled by the
Serial number of the set machine is used for factory, no modification is allowed.
controlling the machine.
WA320, 320PZ-6 10-910 21

Input and output signals 1
AMP070-20P[CN-L24]
Pin No. Specifications I/O Group Form of use Signal name Remarks
1 (NC)
2 (NC)
3 (NC)
Constant power
4 NSW power supply (+24 V) I NSW power supply (+24 V)
supply (+24 V)
Constant power
5 NSW power supply (+24 V) I NSW power supply (+24 V)
supply (+24 V)
Power supply
6 SW power supply (+24 V) I SW power supply (+24 V)
(+24 V)
Power supply
7 SW power supply (+24 V) I SW power supply (+24 V)
(+24 V)
8 (NC)
9 GND I GND GND
10 GND I GND GND

D_OUT_3
11 O A D/O sink ECSS relay If equipped
(+24 V, sink 200 mA)
D_OUT_2
12 O A D/O sink Back-up lamp
(+24 V, sink 200 mA)
13 (NC)
D_OUT_0
14 O A D/O sink Alarm buzzer
(+24 V, sink 200 mA)
15 (NC)
16 (NC)
17 GND I GND GND
18 GND I GND GND
19 GND I GND GND
20 GND I GND GND
10-910 22 WA320, 320PZ-6

AMP070-18P(1)[CN-L25]
D_IN_0
1 I B D/I (+24 V) Head lamp
(24 V, 5 mA)
D_IN_2
2 I B D/I (+24 V) Starting switch C signal
(24 V, 5 mA)
3 (NC)
D_IN_6
4 I B D/I (+24 V) Quick coupler If equipped
(24 V, 5 mA)
D_IN_8
5 I B D/I (+24 V) ECSS switch If equipped
(24 V, 5 mA)
6 (NC)
D_IN_12
7 I C D/I (+24 V) Turn signal lamp, right
(NSW24 V, 5 mA)
D_IN_14
8 I C D/I (+24 V) U switch
(NSW24 V, 5 mA)
9 GND O GND Signal GND
D_IN_1 Cooling fan automatic reverse
10 I B D/I (+24 V)
(24 V, 5 mA) rotation switch (manual)
11 (NC)
12 (NC)
13 (NC)
D_IN_9 Cooling fan automatic reverse
14 I B D/I (+24 V) If equipped
(24 V, 5 mA) rotation switch (automatic)
15 (NC)
D_IN_13
16 I C D/I (+24 V) Turn signal lamp, left
(NSW24 V, 5 mA)
D_IN_15
17 I C D/I (+24 V) t switch
(NSW24 V, 5 mA)
A_IN_0
18 I H A/I Alternator L signal
(0 30 V)
AMP070-12P(1)[CN-L26]
D_IN_16
1 I D D/I (GND) Brake oil pressure
(24 V/GND, 5 mA)
2 (NC)
D_IN_20
3 I D D/I (GND) Air cleaner clogging
(24 V/GND, 5 mA)
D_IN_22
4 I D D/I (GND) Traction control switch (S mode)
(24 V/GND, 5 mA)
D_IN_24
5 I E D/I (GND) HST oil filter clogging
(24 V/GND, 5 mA)
6 GND O GND Sensor ground
D_IN_17
7 I D D/I (GND) ECSS cut off switch If equipped
(24 V/GND, 5 mA)
D_IN_19
8 I D D/I (GND) (service mode 2 and 3)
(24 V/GND, 5 mA)
D_IN_21
9 I D D/I (GND) ECSS cutoff switch dummy If equipped
(24 V/GND, 5 mA)
10 (NC)
D_IN_25
11 I E D/I (GND) (optional switch)
(24 V/GND, 5 mA)
A_IN_1
12 I H A/I Clearance lamp and tail lamp
(0 30 V)
WA320, 320PZ-6 10-910 23

AMP070-18P(2)[CN-L27]
D_IN_26
1 I E D/I (GND) Parking brake
(24 V/GND, 5 mA)
D_IN_28 Parking brake left-unapplied
2 I E D/I (GND)
(24 V/GND, 5 mA) prevention
D_IN_30
3 I E D/I (GND) Normal emergency steering If equipped
(24 V/GND, 5 mA)
4 (NC)
D_IN_34
5 I F D/I (GND) Dimmer switch
(24 V/GND, 5 mA)
D_IN_36
6 I G D/I (GND) Parking brake dummy
(24 V/GND, 5 mA)
D_IN_38
7 I G D/I (GND) < switch
(24 V/GND, 5 mA)
8 (NC)
9 GND O GND GND

D_IN_27
10 I E D/I (GND) Coolant level
(24 V/GND, 5 mA)
D_IN_29
11 I E D/I (GND) Engine oil level
(24 V/GND, 5 mA)
12 (NC)
13 (NC)
D_IN_35 Parking brake left-unapplied
14 I F D/I (GND)
(24 V/GND, 5 mA) prevention dummy
D_IN_37
15 I G D/I (GND) > switch
(24 V/GND, 5 mA)
D_IN_39
16 I G D/I (GND) Operation of emergency steering If equipped
(24 V/GND, 5 mA)
17 (NC)
18 (NC)
AMP070-12P(2)[CN-L28]
A_IN_2
1 I J A/I Fuel level sensor
(high-resistance input)
A_IN_4
2 I J A/I HST oil temperature sensor
3 (NC)
4 (NC)
5 (NC)
6 GND O GND GND

A_IN_3
7 I J A/I Brake oil temperature sensor
8 (NC)
9 (NC)
10 (NC)
11 GND O GND (GND)
12 (NC)
10-910 24 WA320, 320PZ-6

AMP070-12P(3)[CN-L29]
1 (NC)
2 (NC)
3 CAN (+) I/O P CAN CAN (+)
4 (NC)
5 (NC)
6 GND O GND GND
7 (NC)
8 CAN () I/O P CAN CAN ()
9 (NC)
10 (NC)
11 (NC)
12 (NC)
AMP070-14P[CN-L30]
1 (NC)
2 (NC)
3 (NC)
4 (NC)
5 (NC)
6 (NC)
7 (NC)
8 (NC)
9 (NC)
10 (NC)
11 (NC)
12 (NC)
13 (NC)
14 (NC)
WA320, 320PZ-6 10-910 25

AMP040-8P
Do not connect wiring
1 (NC)
harness on machine
2 (NC)
harness on machine
3 (NC)
harness on machine
4 (NC)
harness on machine
5 (NC)
harness on machine
6 (NC)
harness on machine
7 (NC)
harness on machine
8 (NC)
harness on machine
Setting switches (On circuit board)

Switch
Specifications I/O Group Form of use Signal name Remarks
No.
1 16 Posi rotary switch 1 I (spare)
1 26 Posi DIP switch 1 I (spare)

5

6
10-910 26 WA320, 320PZ-6

WA320, 320PZ-6 10-910 27

SEN04182-02

2009 KOMATSU
All Rights Reserved
10-910 28
SEN04183-03
WA320, WA320PZ-6
SEN04183-03
WHEEL LOADER
Shop Manual
WA320-6
WA320PZ-6

WA320-6 70001 and up

maintenance standard
Electrical system (HST controller system) .................................................................................................. 2

HST controller ............................................................................................................................................. 18
ECSS system.............................................................................................................................................. 20
KOMTRAX system...................................................................................................................................... 22
Engine starting circuit.................................................................................................................................. 24
Engine stopping circuit................................................................................................................................ 26
Preheating circuit ........................................................................................................................................ 27
Engine output derating function .................................................................................................................. 28
Automatic warm-up function ....................................................................................................................... 28
Parking brake circuit ................................................................................................................................... 30
Coupler plunger control system .................................................................................................................. 32
Max. traction switch .................................................................................................................................... 33
Multi-function knob...................................................................................................................................... 34
Sensor......................................................................................................................................................... 35
WA320, WA320PZ-6 10-920 1

SEN04183-03 Electrical system (HST controller system)
Electrical system (HST controller system)

a Except where otherwise specified, the displayed travel speed in this document represents the one when
20.5-25 tire is worn.
Input and output signals diagram
Travel speed range selector switch Ao o A HST motor 1 solenoid
Variable shift control switch Ao o D HST motor 2 solenoid relay

Operating switch input
Traction control switch Do o A Clutch solenoid
Solenoid output
Directional lever (F, N, R) Do o A Cooling fan motor flow rate control EPC valve
Directional selector switch (F, N, R) Do o D Cooling fan motor reverse rotation solenoid relay
Directional selector switch actuation switch Do o D Directional solenoid (F, R)
Parking brake lever intermediate switch Do o D HST controller power holding relay
Parking brake lever bottom switch Do o D HST safety relay
Speed sensor A Po o C Throttle upper limit (Eng_con)

Sensor input
Speed sensor B Po o C Throttle lower limit (Eng_con)
HST oil pressure sensor Ao o C Automatic warm-up cancel (Eng_con)
Engine speed (Eng_con) Co

Monitor display information (Eng_con)
Accelerator pedal angle (Eng_con) Co o C (Failure code, real-time monitor, pilot lamp, alarm
buzzer, etc.)
Coolant temperature (Eng_con) Co
CAN output
Co o C Travel speed (Mon)
HST controller
Boost temperature (Eng_con)
o C ECSS operation command (Mon)

Monitor display information (Eng_con)
(Failure code, real-time monitor, pilot lamp, alarm Co o C Back-up lamp operation command (Mon)
buzzer, etc.)
o C Failure code signal (Mon)
HST oil temperature (Mon) Co o C Real-time monitor signal (Mon)
Cooling fan manual reverse rotation (Mon) Co o C Pilot lamp signal (Mon)
Cooling fan automatic reverse rotation (Mon) Co o C Load frequency information (KOMTRAX)
CAN input
ECSS (Mon) Co
Traction control S mode (Mon) Co
Model selection (Mon) Co
Option device selecting (Mon) Co

Automatic fan switching cycle to reverse rotation
Co
(Mon)
Reverse rotation duration (Mon) Co
Traction control level (A, B, C) (Mon) Co
HST selector (A, B) (Mon) Co
Tire selection (Mon) Co

Service meter (Mon) Co
Eng_con: Engine controller

Mon: Machine monitor
KOMTRAX: KOMTRAX terminal
A: Analog signal
D: Digital signal
P: Pulse signal
C: CAN signal
10-920 2 WA320, WA320PZ-6

Electrical system (HST controller system) SEN04183-03
HST controller gear shifting control function

Gear shifting function
q Receiving the travel speed range selector signal and the variable shift control signal, this function controls
HST motor 1, HST motor 2 and transfer clutch in such that the maximum travel speed suited for the given
state is produced.
Selected
Travel speed range Clutch solenoid HST motor 1 HST motor 2 Variable shift control
speed
(km/h) output solenoid output solenoid output signal input voltage (V)
range
0 13
(depends on the Fixed to MAX
1st ON MAX MID 0.9 4.1
variable shift control (ON)
signal)
Fixed to MAX
2nd 0 13 ON MAX MID
(ON)
Fixed to MAX
3rd 0 18.7 ON, OFF MAX 0
(ON)
Fixed to MAX
4th 0 38 ON, OFF MAX 0 Variable
(ON, OFF)
Relationship between accelerator pedal angle

and travel speed (A) for starting transfer clutch
switching modulation
Transfer clutch
0 65 65 90 90 100
Engaged o Disen-
8 km/h 8 10 km/h 10 km/h
gaged (B)
Disengaged o
7 km/h 7 9 km/h 9 km/h
Engaged (C)
Relationship between accelerator pedal angle

and travel speed (A) for switching HST motor 2
capacity
HST motor 2 Accelerator pedal angle (%)
capacity 0 65 65 90 90 100
Max. fixed (D) 8 km/h 8 10 km/h 10 km/h
Free (E) 9 km/h 9 11 km/h 11 km/h
WA320, WA320PZ-6 10-920 3

1. HST pump 5. Clutch solenoid valve

2. HST motor 1 6. HST motor 1 solenoid valve
3. HST motor 2 7. HST motor 2 solenoid valve
4. Transfer clutch 8. Transfer output shaft
Gear shifting display function

q The HST controller displays the state of input signals related to gear shift on the monitor by sending them
to the machine monitor via network.
1. Directional indicators
The directional lever position pilot lamps of the machine monitor indicate the state of the directional lever
based on the input data to the HST controller.
When the directional lever is at the neutral position and no input signal is sent to the HST controller, all the
directional lever position pilot lamps of the machine monitor go off.
If two independent signals were sent to the HST controller by accident, two directional lever position pilot
lamps of the machine monitor may turn on at the same time.
As the directional lever is set to "R (reverse)" the HST controller activates the backup lamp relay to light
the reverse lamp and sound the back-up alarm.
2. Speed range indicator

The travel speed range selector switch position pilot lamp of the machine monitor displays the state of the
travel speed range selector switch being sent to the HST controller.
Variable shift control system

q When the travel speed range selector switch is set to the 1st speed, the variable shift control signal allows
adjusting the maximum speed in the range of 4 - 13 km.
10-920 4 WA320, WA320PZ-6

Transfer clutch control function

q In order to reduce impacts resulting from connecting the transfer clutch or to prevent inadequate torque
due to delayed connection of the transfer clutch, this function adjusts the clutch oil pressure to an optimum
level for the machine state (travel speed, travel load, HST oil temperature, directional lever and accelerator
opening ratio) by referencing the modulation table of the HST controller.
q In order to reduce lack of the torque, this function maintains the modulation control when the clutch is re-
leased.
Traction control function

q Receiving the traction control signal, this function derates the maximum capacity of HST motor 1 to control
the traction force.
q "Traction level selecting function" of the machine monitor allows selecting a desired traction force out of 3
levels (A, B and C).
q The traction control operation pilot lamp remains turned on as long as the traction control operation is con-
tinued.
a For the operating method of this function, see the "Operation and maintenance manual".
S mode function
q Receiving the S mode signal, this function reduces the maximum capacity of HST motor 1 and the upper
limit of the throttle opening ratio in order to secure an optimum drive force for the dozing work on very slip-
pery road surface (on the snow-covered road, sandy terrain, etc.).
q This function restricts sudden start in forward travel by reducing skidding of tires through control of the
drive force. And by securing smooth start of the machine, this function offers enhanced operating perfor-
mance.
q The S mode operation pilot lamp of the machine monitor remains lighted as long as the S mode operation
is continued.
a The traction force control in the S mode is enabled when the directional lever is set to the "forward" position
and the machine is traveling forward or stopped.
a For the operating method of this function, see the "Operation and maintenance manual".
Features
Switch
Pilot lamp Traction level Road condi- Guideline
position Traction Material
tion
1
OFF 1
(OFF) Suitable for loading work. Improves work effi-
Powerful Hard-packed Un-slippery ciency and provides antislip by selecting trac-
2A
I I I tion level depending on material and road
2 2 O O O conditions.
2B
(ON) (ON) Soft Loose Slippery
Select when operating with the special attach-
2C
ment which requires small traction force.
Provides the best driving force on very slip-
Select when the machine tends to slip when
3 3 pery road surfaces covered by snow, sand,
3 forwarding, such as on snow or sand covered
(S mode) (ON) etc. Prevents the tires from slipping to facili-
road surface.
tate work.
WA320, WA320PZ-6 10-920 5

The maximum traction force available when the

travel speed range selector switch is set to "1st"
and the traction control switch is set to "ON"
q When the travel speed range selector switch (1)

is set to "1st" and the variable shift control switch
(2) is turned fully to the left, setting the traction
control switch to the ON position does not re-
duce the maximum traction force. In this case,
the maximum traction force remains at the same
level as when the traction control switch is set to
the "OFF" position.
q As clockwise turning of the variable shift control
switch (2) is continued, the traction force ap-
proaches the maximum traction force being set
from the "Traction level selecting function" of the
machine monitor.
q It is possible to obtain the maximum traction
force, which has been set from the traction con-
trol switch and "Traction level selecting function"
of the machine monitor, by turning the variable
shift control switch (2) fully to the right.
10-920 6 WA320, WA320PZ-6

Max. traction function

q Pressing the max. traction switch while the traction control is "ON" or the S mode is selected cancels the
traction control or the S mode temporarily to increase the maximum drawbar pull.
q If the directional lever or directional selector switch is operated, or the max. traction switch is pressed again
while the traction control or S mode is cancelled from the max. traction switch, the traction "ON" state or
S mode is restored.
q As long as the traction control or S mode is cancelled from the max. traction switch, the traction control
operation pilot lamp or S mode operation pilot lamp of the machine monitor remains turned off.
a Holding down the max. traction switch for a second or longer cancels the traction control or S mode as
long as it is held down. The traction control or S mode is restored at the moment the switch is released.
a If the traction control is sequentially turned "ON" and "OFF" in less than a second, the traction control or
S mode is cancelled temporarily just like the max. traction switch is held down for less than a second.
1. Traction control switch

2. Max. traction switch
3. HST controller
4. Machine monitor
a. Traction control switch signal

b. S mode signal
c. CAN signal
WA320, WA320PZ-6 10-920 7

HST controller protection function

HST motor 1 overrun prevention function 1
q If the 1st or 2nd speed is selected while the machine is traveling at a high speed with the travel speed
range selector switch being set to the 3rd or 4th, the transfer clutch is engaged during the high speed trav-
el, preventing HST motor 1 to overrun beyond the allowable rotating speed.
q In order to prevent the overrun, this function disables the gear shift from the 3rd or 4th to the 2nd or 1st
when the transfer clutch is released.
q As above gear shift is disabled, this function generates "OVERRUN PROTECT" message on the machine
monitor character display and activates the alarm buzzer.
q This error status is reset as the transfer clutch is engaged or the travel speed range selector switch is set
to an allowable gear shift position.
a Above error message is not sent to KOMTRAX terminal.
Gear shift operation Behavior after gear shift
Switch
Switch Actual speed
position State of transfer clutch Display of
position after range after Remarks
before gear after gear shift message
gear shift gear shift
shift
2nd 2nd
Not dis- Gear shift available independent of
1st Connected 3rd 3rd
played traveling speed
4th 4th
1st 1st
Not dis- Gear shift available independent of
2nd Connected 3rd 3rd
played traveling speed
4th 4th
1st 1st
Not dis-
Connected 2nd 2nd
played
4th 4th Gear shift to 1st or 2nd becomes
3rd 1st 3rd available only when the clutch is
(*1) Displayed
2nd 3rd engaged.
Other than the con-
Not dis-
nected state 4th 4th
played
1st 1st
Not dis-
Connected 2nd 2nd
played
3rd 3rd Gear shift to 1st or 2nd becomes
4th 1st 3rd available only when the clutch is
(*1) Displayed
2nd 3rd engaged.
Other than the con-
Not dis-
nected state 3rd 3rd
played
*1: The clutch is released including the ongoing clutch connection modulation (*2) and clutch release modulation state.
*2: It indicates the period 1.2 seconds after the clutch connection modulation has been started while the machine is trav-
eling at 7 up to 9 km/h.
Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switch-
ing modulation
Transfer clutch
0 65 65 90 90 100
Engaged o Disen-
8 km/h 8 10 km/h 10 km/h
gaged (B)
Disengaged o
7 km/h 7 9 km/h 9 km/h
Engaged (C)
10-920 8 WA320, WA320PZ-6

HST motor 1 overrun prevention function 2

q Downhill travel at 1st or 2nd gear speed tends to allow the machine to increase the travel speed. This func-
tion prevents the rotational speed of HST motor 1 goes beyond the allowable rotating speed.
q In order to restrict the travel speed, the function controls the HST motor 1 capacity to the allowable maxi-
mum if the travel speed goes beyond 14 km/h.
Travel speed control function

q Downhill travel at a high speed tends to allow the machine to exceed the speed limit because the rotational
speed of HST motor 2, axle and engine goes beyond the allowable rotating speed.
q In order to restrict the travel speed, the function fixes the HST motor 2 capacity to the allowable maximum
if the travel speed goes beyond 40 km/h.
q As the travel speed is controlled, this function generates "OVERRUN PROTECT" message on the ma-
chine monitor character display and activates the alarm buzzer.
q This error state is reset as the travel speed goes below 39.5 km/h or less.
a Above error message is not sent to KOMTRAX terminal.
Engine overrun prevention function

q If the HST motor 2 capacity reaches its allowable rotating speed when the machine travels downhill at a
high speed, the HST pump and engine rotation becomes high speed. This function prevents the HST mo-
tor 2 to overrun beyond the allowable rotating speed.
q This function prevents the HST motor 2 solenoid valve to be set to "ON" (fixed to MAX) when the travel
speed is more than 30 km/h and the engine speed is more than 2,925 rpm. If the HST motor 2 solenoid
valve is already set to "ON", the solenoid valve is forcibly set to "OFF" to prevent the HST pump and engine
from overrun.
q This function is canceled when the engine speed goes below 2,825 rpm.
q As the travel speed is controlled, this function generates "OVERRUN PROTECT" message on the ma-
chine monitor character display and activates the alarm buzzer.
Neutralizer function
q When the parking brake lever is pulled (the switch at the bottom of the parking brake lever is "OFF"), this
function, independent of the directional lever position, holds HST pump at the neutral in order to prevent
dragging of the parking brake.
Economy operation pilot lamp function

q In order to prompt the operator for the low fuel consumption operation, this function lights up the economy
operation pilot lamp as long as the low fuel consumption operation is continued.
q The economy operation pilot lamp lights up as the opening ratio of the accelerator pedal is maintained at
less than 75% for 0.5 seconds or longer.
q The economy operation pilot lamp can be constantly turned off by selecting "NO ADD" for "4: ECO LAMP"
item from the "Optional device selecting function" of the machine monitor.
a For the setting procedure, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.
WA320, WA320PZ-6 10-920 9

Cooling fan control function
1. HST controller Input and output signals

2. Machine monitor HST controller
3. Engine controller a. CAN signal
4. Cooling fan pump b. Cooling fan motor flow rate control signal
5. Cooling fan motor c. Cooling fan reverse signal
5a. Cooling fan motor flow rate control EPC
valve Machine monitor
5b. Cooling fan reverse solenoid valve d. Cooling fan automatic reverse signal
6. Cooling fan reverse switch e. Cooling fan manual reverse signal
7. Machine monitor mode selector switch 1 f. CAN signal
8. Machine monitor mode selector switch 2 g. "U" switch signal
9. Cooling fan reverse solenoid valve relay h. "t" switch signal
10. HST oil temperature sensor i. ">" switch signal
11. Boost pressure and oil temperature sensor j. "<" switch signal
12. Coolant temperature sensor k. HST oil temperature signal
13. Engine speed sensor
14. Engine Engine controller
15. Radiator l. CAN signal
m. Boost pressure and temperature signal
n. Engine speed signal
o. Coolant temperature signal
10-920 10 WA320, WA320PZ-6

Fan control
q Employment of the hydraulically driven cooling fan and the control of the flow rate of the hydraulic motor
allow reducing the horsepower loss and noises as well as cutting the warm-up operation time in a low tem-
perature environment.
q Engine speed, coolant temperature and boost air temperature received by the engine controller, and the
information of HST oil temperature received by the machine monitor are sent to the HST controller via the
network.
q Based on the received information, the HST controller sends the signal current to the cooling fan motor
flow rate control EPC valve in order to set the fan speed to a level suitable for the respective temperature
levels and the engine speed.
Fan speed in accordance with temperature
*1: The target fan speed is determined based on the coolant temperature, HST oil temperature or boost air
temperature data, whichever is the highest.
*2: Within this range, the fan speed is set according to the coolant temperature, HST oil temperature and
boost air temperature.
*3: When the boost air temperature is at the lower limit or when the HST oil temperature is low, the fan speed
is decreased to increase the oil and coolant temperature (heater spurting out temperature) and cut the
warm-up operation time.
(the fan speed in this area is controlled based on the hysteresis of each temperature.)
WA320, WA320PZ-6 10-920 11

Control at start of engine

q In order to protect the fan from being stopped by low oil temperature or settled snow or dusts, the fan
speed is temporarily increased immediately after the engine is started to aid start of the fan rotation.
q After the basic control is turned on, normal fan control is carried on based on the procedure described in
the section of "Fan speed in accordance with temperature".
a The fan control (derating of the minimum fan speed) at start of the engine is conducted only once after the
starting switch has been set to "ON". When, however, the starting switch was turned "OFF" once and then
turned "ON" again, the control is implemented one more time if the control starting conditions are met.
The control (derating of the minimum fan speed) at start of engine is carried out if every condition in the fol-
lowing table is met.
Condition 1 Starting switch is turned "ON".
Condition 2 Engine speed is 700 rpm or above.

Engine is rotating forward.
Condition 3 [above, however, does not apply as a condition if the controller recognized that switching in the rotating
direction is taking place.]
Condition 4 After the starting switch is turned "ON", the control at start of engine has not been carried out yet.
*1: When the fan speed control conditions at low temperature are not applicable and the minimum boost air
temperature is 20C or above.
Point A: Starting switch is turned "ON" (when engine is stopped)

Point B: Control starting conditions are met
Area C: Minimum fan speed is restricted
Area D: Basic control is turned on
10-920 12 WA320, WA320PZ-6

Fan reverse rotation function

q As the fan reverse rotation switch is pressed for cleaning of the radiator core, the cooling fan reverse ro-
tation solenoid valve of the cooling fan motor is activated, reverse rotating the fan.
1. Fan manual reverse rotation function

The operator can select the desired fan rotation direction by pressing the fan reverse rotation switch to
"MANUAL" for 0.5 seconds or longer.
As long as switching of the fan rotation direction is taking place, the pilot lamps of the machine monitor
keeps blinking to inform the operator that the switching is underway. And when the fan rotation is reversed
responding to the high engine speed, high coolant or oil temperature, this lamp also keeps on blinking until
the preparation for switching is completed.
As the fan rotation switching condition is met, this function sends the accelerator opening ratio-restricting
signal to the engine controller so that the engine speed may not reach 1,200 rpm or above while the
switching is underway. Above control, however, is not applicable when the HST oil temperature is 30C
or above.
The pilot lamp of the machine monitor keeps on blinking as long as the reverse rotation of the fan is
continued.
The fan rotation is switched from "forward" to "reverse" as every condition in the following table is met.
Condition 1 The fan reverse rotation switch was set to "MANUAL" for 0.5 seconds or longer.
Condition 2 Engine speed over 500 rpm and below 1,200 rpm.
(*1) [above is required to prevent generation of peak pressure in the process of switching the direction.]
Coolant temperature is below 102C.
Condition 3
[above is required to prevent overheating.]
HST oil temperature is below 100C.
Condition 4
Boost air temperature is below 80C.
Condition 5
30 seconds minimum have elapsed since the engine is started (since the engine speed reached 500
Condition 6 rpm or above).
[above is required to secure the oil to be supplied to the brake accumulator.]
The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met.
Condition 1 While the fan is rotating reverse, the fan reverse switch was again set to "MANUAL" and the engine
(*1) speed went to below 1,200 rpm.
Condition 2 After the fan rotated in the reverse direction for 10 minutes, the engine speed went to less than
(*1) 1,200 rpm.
Condition 3 The engine has stopped.
*1: The engine speed-related requirement (1,200 rpm) is exempted when the HST oil temperature is
30C or above.
2. Overheat prevention function

If overheat in the coolant temperature, HST oil temperature or boost air temperature was recognized while
the fan was rotating reverse, the reverse rotation is forcibly stopped and the forward rotation is turned on
in order to increase the air flow to the radiator.
3. Fan speed during reverse rotation

While the reverse fan rotation is continued, this function sets the fan speed to the maximum by cutting off
the command current (sets the command current to 0 mA) to the fan motor flow rate control EPC valve.
Setting the fan speed to the maximum increases air flow to the radiator core maximum, making the
cleaning work easier.
WA320, WA320PZ-6 10-920 13

4. Fan automatic reverse rotation function

(if equipped)
Setting the fan reverse rotation switch to "AUTO" allows changing the fan rotation direction switching cycle
and the reverse rotation duration at a specific interval.
As long as switching of the fan rotation direction is taking place, the pilot lamps of the machine monitor
keeps blinking to inform the operator that the switching is underway. And when the fan rotation is reversed
responding to the high engine speed, high coolant or oil temperature, this lamp also keeps on blinking until
the preparation for switching is completed.
The pilot lamp of the machine monitor keeps on blinking as long as the reverse rotation of the fan is
continued.
The fan rotation is switched from "forward" to "reverse" as every condition in the following table is met.
Condition 1 The fan reverse rotation switch is set to "AUTO".
Coolant temperature is below 102C.

Condition 2
HST oil temperature over 13C and below 100C.
Condition 3
[the upper limit of 95C is required to prevent overheating.]
Boost air temperature is below 80C.
Condition 4
30 seconds minimum have elapsed since the engine is started (since the engine speed reached 500
Condition 5 rpm or above).
[above is required to secure the oil to be supplied to the brake accumulator.]
Condition 6 The fan rotation direction switching cycle has elapsed.
The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met.
Condition 1 Set the fan reverse rotation switch to any position other than "AUTO" during the reverse fan rotation.
Condition 2 The specified reverse rotation duration elapses.
Condition 3 The engine has stopped.
5. Adjustment of the automatic fan switching cycle to reverse rotation and duration
(if equipped)
Any cycle is settable for the switching cycle of fan rotation direction and also any duration is settable for
the reverse rotation duration by adjusting the items "Adjustment of interval of fan automatic reverse oper-
ation" and "Adjustment of continuance of fan automatic reverse operation" with the adjusting function of
the machine monitor.
a For the adjustment procedure, see "Special functions of machine monitor (EMMS)" in Testing and ad-
justing.
10-920 14 WA320, WA320PZ-6

WA320, WA320PZ-6 10-920 15

System circuit diagram

a Items marked with "*1" in drawing may or may not installed.
10-920 16 WA320, WA320PZ-6

WA320, WA320PZ-6 10-920 17

SEN04183-03 HST controller
HST controller
DEUTSCH-40P [CN-HST]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 VB (controller power) Input 21 GND (controller GND)
2 Starting switch ACC signal Input 22 HST sensor power 5 V Input
3 Wake up Input 23 Travel speed adjusting dial Input
4 Directional selector switch F Input 24 Directional selector switch R Input
Directional selector switch operating
5 Directional lever N Input 25 Input
switch
6 Parking brake lever intermediate switch Input 26 Speed sensor A Input
7 HST controller power holding relay Output 27 HST motor 2 solenoid relay Output
8 NC 28 CAN0_H Input/Output
9 Clutch solenoid Output 29 Cooling fan motor flow rate control EPC Output
10 HST pump F solenoid Output 30 VIS (solenoid power) Input
11 VB (controller power) Input 31 GND (controller GND)
12 Starting switch ACC signal Input 32 GND (sensor GND)
13 Alternator L signal Input 33 HST oil pressure sensor Input
14 Directional selector switch N Input 34 Directional lever F Input
15 Directional lever R Input 35 Traction control switch Input
16 Parking brake lever bottom switch Input 36 Speed sensor B Input
Cooling fan motor reverse rotation sole-
17 HST safety relay Output 37 Output
noid relay
18 NC 38 CAN0_L Input/Output
19 HST motor 1 solenoid Output 39 Travel speed range selector switch Input
20 HST pump R solenoid Output 40 SOL_COM (solenoid common GND)
10-920 18 WA320, WA320PZ-6

HST controller SEN04183-03
WA320, WA320PZ-6 10-920 19

SEN04183-03 ECSS system
ECSS system
(If equipped)
a ECSS: Abbreviation for Electronically Controlled Suspension System
1. HST controller Outline

2. Machine monitor q When the machine travels at high speed, the
3. ECSS switch damping effect of the accumulator charged with
4. ECSS relay high-pressure gas and the automatic control of
5. ECSS solenoid valve the lift cylinder circuit relief pressure under each
6. Speed sensor travel condition damp the vertical movement of
7. Bucket tilt PPC oil pressure switch the work equipment and reduce rocking of the
8. Lift arm lower PPC oil pressure switch chassis. As a result, the operator comfort is im-
proved, spillage of material is prevented, and the
Input and output signals working efficiency is improved.
HST controller
a. Travel speed signal A Setting method
b. Travel speed signal B q The ECSS can be enabled only when "ADD" is
c. CAN signal selected for "5: E.C.S.S." item from the "Optional
device selecting function" of the machine moni-
Machine monitor tor.
d. CAN signal a For the setting procedure, see "Special functions
e. ECSS switch "ON" signal of machine monitor (EMMS)" in Testing and ad-
f. ECSS operation signal justing.
g. ECSS cut off signal
h. ECSS cut off (dummy) signal
10-920 20 WA320, WA320PZ-6

ECSS system SEN04183-03
Operation
q The operating condition of ECSS is as follows. q The operating condition of PPC oil pressure
ECSS opera- switch is as follows.
ECSS switch Travel speed [km/h]
tion signal
OFF 0 Max.
OFF
(*2) Max. 4
ON
(*1) Min. 5 ON
PPC oil pressure switch

A B
operating point
Operating oil pressure 0.29 0.49
[MPa{kg/cm2}] {3} {5}
ECSS switching point A B

(*2) (*1)
Travel speed [km/h]
4 5
*1. It is allowed to select any travel speed at the
ECSS switching point (B) in the range of 5 to 8 km/h
by adjusting the items "Adjustment of ECSS opera-
tion travel speed" with the adjusting function of the
machine monitor.
*2. The travel speed available at ECSS switching
point (A) is obtained by deducting 1 km/h from that
available at the switching point (B) (namely, 4 - 7
km/h).
a When tilting the bucket or lowering the lift arm,
turn "OFF" the ECSS operation signal to reset
ECSS.
(WA320PZ-6)
a For the adjustment procedure, see "Special
functions of machine monitor (EMMS)" in Test-
ing and adjusting.
WA320, WA320PZ-6 10-920 21

SEN04183-03 KOMTRAX system
KOMTRAX system
q KOMTRAX terminal wirelessly transmits various machine information. KOMTRAX operators refer to the
information in their offices and can provide customers with various services accordingly.
a To be provided with the KOMTRAX terminal service, it is necessary to sign up separately.
KOMTRAX terminal transmits the following information:

1. Operation map
2. Service meter
3. Location information
4. Error history
etc.
10-920 22 WA320, WA320PZ-6

KOMTRAX system SEN04183-03
KOMTRAX terminal
Model: TC301
q Satellite wave is used.
1. Communication antenna connector

2. GPS antenna connector
3. Machine harness connector (DEUTSCH-40P)

DEUTSCH-40P [CN-L80]
Input/Output Input/Output
Pin No. Signal name Pin No. Signal name
signal signal
1 NC 21 Operation mode selection 1 Input
2 NC 22 Operation mode selection 2 Input
3 NC 23 NC
4 NC 24 NC
5 NC 25 NC
6 NC 26 NC
7 CAN0_ L Input/Output 27 Starting switch C signal Input
8 CAN0_H Input/Output 28 Alternator L signal Input
9 NC 29 NC
10 NC 30 NC
11 NC 31 NC
12 NC 32 NC
13 NC 33 NC
14 NC 34 NC
15 NC 35 NC
16 NC 36 Starting switch ACC signal Input
17 NC 37 Power source GND
18 NC 38 Power source GND
19 NC 39 Constant power supply (24 V) Input
20 Immobilizing signal Output 40 Constant power supply (24 V) Input
Outline
q The KOMTRAX terminal can send information q There are the LED lamp and the 7-segment indi-
via wireless communication antenna, acquiring cator lamp in the display area, and these lamps
various information of the machine from the net- are used for the testing and the troubleshooting.
work signal in the machine and the input signal. q KOMTRAX terminal can be used only in the
Also, the controller incorporates CPU (Central countries specified by the communication con-
Processing Unit) and provides the wireless com- tract.
munication function and the GPS (Global Posi-
tioning System) function.
WA320, WA320PZ-6 10-920 23

SEN04183-03 Engine starting circuit
Engine starting circuit
1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to secure
3. Slow-blow fuse safety when the engine is started.
4. Fuse box 1 q The engine can not be started while the di-
5. Fuse box 2 rectional lever is at any position other than N
6. Starting switch (neutral).
7. Directional lever q When the directional selector switch operat-
8. Neutral safety relay ing switch is turned "ON", the directional le-
9. KOMTRAX engine cut-off relay (if equipped) ver and the directional selector switch must
10. HST controller power holding relay be at "N (neutral)" to start the engine.
11. Starting motor safety relay (if equipped)
12. Starting motor
13. Alternator 2. The KOMTRAX engine cut-off circuit is
14. HST controller employed to disable the engine from starting
15. Engine controller when the KOMTRAX terminal receives an
16. Machine monitor engine cut-off command issued through external
17. KOMTRAX terminal (if equipped) operation.
18. Engine controller cut-off relay (if equipped)
19. CAN resistor
20. Directional selector switch operating switch (if
equipped)
21. Directional selector switch (if equipped)
10-920 24 WA320, WA320PZ-6

Engine starting circuit SEN04183-03
Operation
1. When starting switch is turned "ON"
q As the starting switch is turned "ON", termi-
nals B and BR of the starting switch are
closed and the current flows from the battery
through the starting switch and battery relay
coil to the ground, thereby closing the contact
of the battery relay. As a result, the power is
supplied to each circuit of the machine.
At this time, the ACC signal is sent from
terminal ACC of the starting switch to the
engine controller, readying the engine for
startup.
2. Neutral safety circuit

q Setting the directional lever to "N (neutral)"
conducts the current from contact N of the di-
rectional lever to the neutral safety relay to
activate it.
q When the directional selector switch is used
(when the directional selector switch operat-
ing switch is turned "ON"), if both the direc-
tional lever and directional selector switch
are at "N (neutral)" at this point, the neutral
safety relay is activated.
(if equipped)
3. When starting switch is set to "START"

q As the starting switch is set to "START", the
current flows through the starting switch ter-
minal C, KOMTRAX engine cutoff relay and
neutral safety relay to the starting motor safe-
ty relay to start the engine.
q When the directional lever is set to any posi-
tion other than "N (neutral)", the neutral safe-
ty relay is not activated and interrupts the
engine startup.
q When the directional selector switch is used
(when the directional selector switch operat-
ing switch is turned "ON"), if either of the di-
rectional lever and the directional selector
switch is not at "N (neutral)", the neutral safe-
ty relay is not activated and thus the engine
is not started.
(if equipped)
q As KOMTRAX terminal receives the exter-
nally applied engine cut-off command,
KOMTRAX engine cut-off relay is activated,
shutting down the circuit from the starting
switch terminal C to the starting motor safety
relay. Thus, engine start-up becomes un-
available.
(if equipped)
WA320, WA320PZ-6 10-920 25

SEN04183-03 Engine stopping circuit
Engine stopping circuit
Operation
q Setting the starting switch to "OFF" cuts off ACC
signal from the starting switch terminal ACC to
the engine controller.
q Although ACC is cut off, the engine controller
keeps the engine controller cut-off relay working
to maintain the current flow to the engine control-
ler until its internal processing is complete.
q As ACC signal is cut off, the engine lowers its
speed and stops. At the same time, the alterna-
tor stops power generation, stopping supply of
the voltage from the alternator terminal L.
And the current from the starting switch terminal
BR is also stopped and the contacts of the
battery relay are opened. Consequently, the
power supplied to each circuit of the machine is
stopped.
10-920 26 WA320, WA320PZ-6

Preheating circuit SEN04183-03
Preheating circuit
1. Battery Operation
2. Battery relay q Set the starting switch to "ON" to start the engine
3. Slow-blow fuse controller. At this time, if intake air temperature is
4. Fuse box 1 -4C or below, the engine controller starts up
5. Starting switch the electrical intake air heater immediately after
6. Engine controller the starting switch is turned "ON" to initiate pre-
7. Machine monitor heating by the electrical intake air heater.
8. Electrical intake air heater relay q The preheating time is set as shown below.
9. Electrical intake air heater
10. Boost pressure and temperature sensor
Outline
q The automatic preheating system is installed so
that the engine will start easily in a cold district.
q The automatic preheating system is capable of
cutting the preheating time short as the starting
switch is set to "ON". This system is also capable
of automatically setting the preheating duration
referencing temperature of intake air.
q Setting the starting switch to "ON" lights the pre-
heater pilot lamp of the machine monitor and
starts preheating of intake air with the electrical
intake air heater.
The engine controller sets the preheating dura-
tion referencing the intake air temperature being
sent from the boost pressure sensor and
temperature sensor.
q The pilot lamp remains turned on as long as pre-
heating is continued. Keep the starting switch in
the "ON" position during this time. Setting the
starting switch to "START" from this state resets
preheating.
WA320, WA320PZ-6 10-920 27

SEN04183-03 Engine output derating function
Engine output derating function Automatic warm-up function

q If the engine controller detects a failure, it pro- q When starting the engine in a cold district, this
tects the engine by derating the engine torque or function warms it up by increasing the engine
speed. low idle speed.
q If the coolant temperature is below 20C at
q Following figure shows the engine torque perfor- starting of the engine, this function increases the
mance when the torque was derated. low idle speed to 1,000 rpm. The condition re-
quired for increasing the low idle speed depends
on the coolant temperature as shown in the fig-
ure below.
A: Derated to approximately 30% of the maximum

torque point
B: Derated to approximately 50% of the rated output
point
The automatic warm-up function is reset and the en-
q Following figure shows the engine torque perfor- gine speed returns to 825 rpm as any of the follow-
mance when the engine speed was derated. ing conditions is met.
The coolant temperature reaches 30C or
Condition 1 above while the automatic warm-up func-
tion is enabled.
The accelerator pedal angle remains at
Condition 2
70% for 3 seconds or more.
The automatic warm-up function remains
Condition 3
being enabled for 30 minutes or more.
The directional lever is set to "Forward" or
"Reverse" while the automatic warm-up
function is enabled.
Condition 4
(When the directional lever is returned to
"Neutral" to stop the machine, the auto-
matic warm-up function restarts.)
A: Derated near to the engine speed at maximum

torque point
10-920 28 WA320, WA320PZ-6

Automatic warm-up function SEN04183-03
WA320, WA320PZ-6 10-920 29

SEN04183-03 Parking brake circuit
Parking brake circuit
1. Parking brake lever intermediate switch

2. Parking brake lever bottom switch
3. HST controller
4. Machine monitor
5. Alarm buzzer
6. HST controller power holding relay
7. HST safety relay
8. Clutch solenoid valve
9. HST motor 1 solenoid valve
10. HST pump forward solenoid valve
11. HST pump reverse solenoid valve
10-920 30 WA320, WA320PZ-6

Parking brake circuit SEN04183-03
Operation
Starting switch position OFF ON
State of engine Stopped Running
Parking brake lever area Free Mid Lock Free Mid Lock Free Mid Lock
Parking brake lever inter-
Close Open Close Open Close Open
mediate switch (1)
Parking brake lever bottom
switch (2)
Close Open Close Open Close Open
[for parking brake pilot
lamp operation]
Parking brake reminder [*1], [*2] [*1]
OFF OFF OFF
caution lamp ON ON
(Reset) (Reset) (Reset)
(Alarm buzzer) (Sounded) (Sounded)
Parking brake pilot lamp OFF OFF ON OFF ON
When the parking brake lever is set to "Mid" po-

sition
q When the parking brake lever is set to the mid
position, the bottom switch (2) is open but inter-
mediate switch (1) is closed.
q The parking brake pilot lamp comes on only
when the starting switch is "ON".
q As bottom switch (2) opens, the output to the for-
ward and reverse solenoid valves of HST pump
is stopped to prevent dragging of the parking
brake. And, at the same time, the directional le-
ver and the directional selector switch are dis-
abled to turn on the machine travel in both the
forward and reverse direction.
When the parking brake lever is set to "Free" po- *1: When the starting switch is turned from "ON" to
sition "OFF":
q When the parking brake lever is set to the free q The parking brake reminder caution lamp turns
position, the intermediate switch (1) and bottom on and the alarm buzzer sounds.
switch (2) are both closed. q The HST controller power holding relay remains
q The parking brake pilot lamp goes off indepen- turned on, conducting current to the HST con-
dent of the given state. troller and maintaining the HST motor 1 solenoid
q The parking brake is released. valve and clutch solenoid valve being activated.
*1: When the starting switch is turned from "ON" to Thus, the machine is protected from slipping
"OFF": through a slope.
q The parking brake reminder caution lamp turns
on and the alarm buzzer sounds. When the parking brake lever is set to "Lock"
q The HST controller power holding relay remains position
turned on, conducting current to the HST con- q Pulling the parking brake lever fully opens both
troller and maintaining the HST motor 1 solenoid the intermediate switch (1) and bottom switch
valve and clutch solenoid valve being activated. (2).
Thus, the machine is protected from slipping q The parking brake pilot lamp comes on only
through a slope. when the starting switch is "ON".

*2: If the parking brake lever is set to any position q The parking brake reminder caution lamp goes
other than "Lock" when the starting switch is at off independent of the given state.
"OFF", the parking brake reminder caution lamp re- q As bottom switch (2) opens, the output to the for-
mains turned off and the alarm buzzer is also not ac- ward and reverse solenoid valves of HST pump
tivated. And HST motor 1 solenoid valve and clutch is stopped to prevent dragging of the parking
solenoid valve remain inactivated. brake. And, at the same time, the directional le-
ver and the directional selector switch are dis-
abled to turn on the machine travel in both the
forward and reverse direction.
q The parking brake is activated.
WA320, WA320PZ-6 10-920 31

SEN04183-03 Coupler plunger control system
Coupler plunger control system

WA320PZ-6
Outline
q The coupler plunger is extracted or retracted by
operating the quick coupler attachment switch to
connect and release each attachment and the
coupler.
Operation
When quick coupler attachment switch is in "Re- When quick coupler attachment switch is in
lease" position "Connect" position
q If the quick coupler attachment switch (1) is set q If the quick coupler attachment switch (1) is set
in the "Release" position, quick coupler solenoid in the "Connect" position, quick coupler solenoid
valve (2) is energized. valve (2) is de-energized.
If the work equipment (bucket) control lever is If the work equipment (bucket) control lever is
moved to the tilt side, the oil flows into the head moved to the tilt side, the oil flows into the bottom
side of coupler plunger (3). Then, coupler side of coupler plunger (3). Then, coupler
plunger (3) is retracted and the attachment and plunger (3) is extracted and the attachment and
coupler are released. coupler are connected.
10-920 32 WA320, WA320PZ-6

Max. traction switch SEN04183-03
Max. traction switch
1. Switch A Function
Mono-lever type : green wiring harness q These switches are installed on the knob of the
2-lever type : white wiring harness work equipment (lift arm) control lever. Switch A
2. Switch B (1) functions as the max. traction switch and
Mono-lever type : white wiring harness switch B (2) does not function.
2-lever type : yellow wiring harness q Both of switch A (1) and switch B (2) are of mo-
3. Wiring harness mentary type, that is, their contacts are closed
only while they are pressed.
WA320, WA320PZ-6 10-920 33

SEN04183-03 Multi-function knob
Multi-function knob
Multi-function mono-lever type
(If equipped)
1. Directional selector switch Function

2. Max. traction switch q Directional selector switch (1) is an alternate
3. Option switch [Reserved] type. Its control signal sent to the HST controller
causes switching between the forward and re-
verse travel.
q Max. traction switch (2) and option switch (3) are
momentary type. Max. traction switch (2) control
signal sent to the HST controller cancels the
traction control temporarily.
10-920 34 WA320, WA320PZ-6

Sensor SEN04183-03
Sensor
Speed sensor
1. Hall IC 5. Heat shrink tube

2. Circuit board 6. Protective tube
3. O-ring 7. Lead wire
4. Housing 8. Connector
Function
q This sensor is installed on the transfer case. It generates two different types of pulses depending on the
rotational direction and speed of the gear.
WA320, WA320PZ-6 10-920 35

SEN04183-03 Sensor
HST oil temperature sensor

Brake oil temperature sensor
1. Connector 2. Plug 3. Thermistor
Function
q The HST oil temperature sensor and the brake oil temperature sensor are installed on the motor 2 hydrau-
lic piping and front axle, respectively. They generate the signal for the change in temperature as variation
in the resistance of the thermistor.
HST oil pressure sensor
1. Sensor 2. Lead wire 3. Connector
Function
q This sensor is installed on the motor 2 solenoid block to measure the oil pressure in the HST circuit and
generate the corresponding signal.
10-920 36 WA320, WA320PZ-6

Sensor SEN04183-03
HST oil filter clogging sensor
1. Terminal 2. Plug
Function
q This sensor is installed on the HST oil filter to monitor the oil pressure before and after the filter. If the pres-
sure goes beyond the specified level, the switch is set to "ON".
Coolant level sensor
1. Float 3. Connector
2. Sensor 4. Sub-tank
Function
q This sensor is installed in the bulkhead. As the coolant goes below the specified level, the float moves
down, and the switch is set to "OFF".
WA320, WA320PZ-6 10-920 37

SEN04183-03 Sensor
Fuel level sensor
1. Connector 5. Spring
2. Float 6. Contact
3. Arm 7. Spacer
4. Body
Function
q This sensor is installed on the side face of the fuel tank. The float moves up and down according to the
fuel level.
The float moves the variable resistor through the arm. The resistance changes according to the operating
angle and signal voltage is generated from the source voltage according to the change of the resistance.
10-920 38 WA320, WA320PZ-6

Sensor SEN04183-03
Accelerator pedal sensor
1. Pedal Output characteristics

2. Connector
3. Sensor
Function
q This sensor is installed on the surface of the
floor. It outputs the accelerator signal or idle val-
idation signal depending on the accelerator ped-
al pressing angle.
Accelerator signal
q Magnitude of the accelerator pedal displace-
ment being detected by the sensor is output in
variable voltage from No. 2 pin.
Idle validation signal

q The sensor detects the accelerator pedal opera-
tion. As the accelerator pedal is released, it out-
puts the signal being entered to No. 5 pin from
No. 4 pin. And as the accelerator pedal is
pressed, it outputs the signal being entered to
No. 6 pin from No. 4 pin.
WA320, WA320PZ-6 10-920 39

SEN04183-03 Sensor
Air cleaner clogging sensor
1. Indicator 3. Adapter
2. Spring 4. Connector
Function
q This sensor is installed in the air cleaner outlet. It outputs the signal as the air cleaner is clogged and the
pressure is decreased to the specified level (negative pressure).
Water-in-fuel sensor
1. Connector 3. Sensor
2. Tube 4. O-ring
Function
q This sensor is installed in the cup of the fuel pre-filter. It outputs the signal as entrainment of water in fuel
is sensed.
10-920 40 WA320, WA320PZ-6

Sensor SEN04183-03
Boom kick-out proximity switch

Bucket positioner proximity switch
1. Switch 3. Operation indication lamp

2. Locknut 4. Connector
Function
q The boom kick-out proximity switch is installed in the lift arm left side connecting part of the front frame.
And the bucket positioner proximity switch is installed on the bucket cylinder. As long as the plate is posi-
tioned on the detector plane, the switch lights up the operation indication lamp and turns itself "ON".
WA320, WA320PZ-6 10-920 41

SEN04183-03
WA320, WA320PZ-6 Wheel loader
2009 KOMATSU
All Rights Reserved
10-920 42
SEN04184-00
WA320-6
WA320PZ-6
WA320-6 70001 and up

20 Standard value table 20
100 Standard service value table

Standard service value table for engine .......................................................................................................... 2
Standard service value table for chassis......................................................................................................... 3
WA320, 320PZ-6 20-100 1

SEN04184-00 Standard service value table for engine
Standard service value table for engine 1
Machine model WA320-6

Engine SAA6D107E-1
Standard value for
Item Measurement conditions Unit Service limit value
new machine
High idle (*) 2,250 50 2,250 50
Engine speed rpm
Low idle (*) 825 25 825 25
Exhaust temperature
All revolution ranges
(Turbocharger outlet tem- C Max. 550 600
(Atmospheric temperature: 20C)
perature)
Intake air pressure At rated output kPa Min. 127 100
(Boost pressure) At aftercooler outlet side {mmHg} {Min. 950} {750}
Engine coolant tempera- At rated output Pollution Max. 12 22

Exhaust gas color
ture: Within operating range At sudden acceleration level % Max. 25 35
Intake valve 0.25 0.05 0.152 0.381
Valve clearance Normal temperature mm
Exhaust valve 0.51 0.05 0.381 0.762
At rated output
kPa Max. 0.98 1.96
Blow-by pressure Engine coolant temperature: Within operating
{mmH2O} {Max. 100} {200}
range
At high idle
SAE0W30E0S Min. 0.29 0.25
Engine coolant tempera-
{Min. 3.0} {2.5}
ture: Within operating range SAE0W40E0S MPa
Oil pressure SAE10W30DH
At low idle {kg/cm2}
SAE15W40DH Min. 0.10 0.07
Engine coolant tempera- SAE30DH {Min. 1.0} {0.7}
ture: Within operating range
Oil temperature All engine speed ranges (Inside oil pan) C 80 110 Min. 120
Deflection under finger pres-
Idler pulley
sure of approx. 58.8 N Auto-tensioner Auto-tensioner
crankshaft pulley
{approx. 6 kg}
Belt tension mm
Deflection under finger Air conditioner com-
pressure of approx. 98 N pressor crankshaft 11 14.5 11 14.5
{approx. 10 kg} pulley
20-100 2 WA320, 320PZ-6

Standard service value table for chassis SEN04184-00
Standard service value table for chassis 1

Category
Standard value for

new machine
N 5.9 (+5.9/0)
13.7 {1.4}
FORWARD {0.6 (+0.6/0)}
N
Directional lever
Operating effort
{kg} 5.9 (+5.9/0)
N
13.7 {1.4}
REVERSE Engine stopped {0.6 (+0.6/0)}
Measure at 10 mm from top of lever
N 45 10 45 20
FORWARD
Travel mm
N
45 10 45 20
REVERSE
7.8 4.9 15.7
Speed switch (Dial switch)
1st 2nd
{0.8 0.5} {1.6}
Engine stopped
N 7.8 4.9 15.7
Operating effort 2nd 3rd Measure at 10 mm from end of switch
{kg} {0.8 0.5} {1.6}
knob
7.8 4.9 15.7
3rd 4th
{0.8 0.5} {1.6}
1st 2nd 30 5 30 10
Travel 2nd 3rd Engine stopped deg. 30 5 30 10
3rd 4th 30 5 30 10
HOLD o 10.8 (+4.9/0) 16.7
RAISE {1.1 (+0.5/0)} {1.7}
RAISE o 7.8 (+4.9/0) 11.8

HOLD {0.8 (+0.5/0)} {1.2}
HOLD o 10.8 (+4.9/0) 16.7

LOWER {1.1 (+0.5/0)} {1.7}
Lift arm
LOWER o
Engine coolant tempera-
HOLD
ture: Operating range
LOWER o N 20.6 (+4.9/0) 31.4
Operating effort Engine speed: Low idle FLOAT {3.2}
{kg} {2.1 (+0.5/0)}
Hydraulic oil temperature:
Work equipment control lever
60 80C FLOAT o 20.6 (+4.9/0) 31.4

HOLD {2.1 (+0.5/0)} {3.2}
HOLD o 12.3 (+4.9/0) 18.6
DUMP {1.25 (+0.5/0)} {1.9}
HOLD o 10.8 (+4.9/0) 16.7
Bucket
TILT {1.1 (+0.5/0)} {1.7}
TILT o 7.8 (+4.9/0) 11.8
HOLD {0.8 (+0.5/0)} {1.2}
HOLD o
37 9 37 9
RAISE
HOLD o
Lift arm 37 9 37 9
Engine coolant tempera- LOWER
ture: Operating range
LOWER o
Travel Engine speed: Low idle mm 13.5 9 13.5 9
FLOAT
60 80C HOLD o
50.5 9 50.5 9
DUMP
Bucket
HOLD o
37 9 37 9
TILT
WA320, 320PZ-6 20-100 3

SEN04184-00 Standard service value table for chassis

Category
Standard value for

new machine
Engine stopped
Play mm 20 20 Max. 60
Machine facing straight to front
Flat, level, straight, dry, and paved road 9.8 2.9 Max.14.7
Operating effort N {kg}
Steering wheel
Engine speed: Low idle (Bucket empty) {1.0 0.3} {Max. 1.5}
Engine speed: High idle
Turns (Not including play) Turns 3.7 0.4 3.7 0.8
Left lock right lock
Low idle Engine started 3.7 0.4 Max. 4.8

Hydraulic oil temperature: Within operat-
Operating time sec.
ing range
High idle Left lock right lock 3.7 0.3 3.7 1
Beginning of 24.5 37.8

Engine started
depression {2.5 3.9}
Accelerator pedal
Operating effort Measure at 150 mm from fulcrum of N {kg}

pedal. 45.5 58.8
Full open
{4.6 6.0}
Neutral (1) a For measuring posture, see Fig. A at end 45 2

Operating of this section
deg.
angle Engine started
stroke () = 1 2 17 2
Operating angle: 20
Engine speed: Low idle 294 30 Min. 238
Operating effort N {kg}
Hydraulic oil temperature: Within operat- {30 3.0} {Min. 24.3}
ing range
Brake pedal
Neutral (1) 50
Operating a For measuring posture, see Fig. B at end
angle of this section
Max. (2) Engine speed: Low idle deg. 30 (+2/0)
Hydraulic oil temperature: Within operat-
Play ing range 51
HST stall 2,210 100 2,210 (+90/200)

Engine speed
Engine coolant temperature: Within oper-

ating range
Hydraulic stall rpm 2,150 100 2,150 (+150/200)
HST oil temperature: 60 80C
Hydraulic oil temperature: 45 55C
HST stall + hydraulic stall 2,030 (+130/200) 2,030 (+230/300)
1st 4 0.2 4 0.3

Power train (HST)
2nd 13 0.7 13 0.9

Travel speed
FORWARD km/h
(Bucket empty)
3rd 18.7 0.9 18.7 1.3
4th 38 1.9 38 (+1.9/2.7)
20-100 4 WA320, 320PZ-6


Category
Standard value for

new machine
1st 4 0.2 4 0.3
2nd 13 0.7 13 0.9

Travel speed
REVERSE km/h
(Bucket empty)
3rd 18.7 0.9 18.7 1.3
4th 38 1.9 38 (+1.9/2.7)
Engine speed: Full speed

High pressure 44.1 1.2 44.1 (+1.2/3.0)
Directional lever: FORWARD
cut-off pressure {450 12} {450 (+10/30)}
Speed switch: 2nd speed
Traction control switch: ON
Low pressure
Engine speed: Full speed
relief pressure
Hydraulic oil temperature: 3.0 (+0.2/0) 3.0 (+0.2/0.1)
(Work equip-
Power train (HST)
45 55C {31 (+2/0)} {31 (+2/1)}

ment PPC cir-
Directional lever: N
cuit pressure)
Engine speed:
Full speed When brake pedal 3.0 (+0.2/0) 3.0 (+0.2/0.1)
HST oil releasing {31 (+2/0)} {31 (+2/1)}
pressure Servo piston Hydraulic oil
control oil pres- temperature:
sure 45 55C When brake pedal Max. 0.6 Max. 0.6
Directional depressing {Max. 6} {Max. 6}
lever: N MPa
{kg/cm2}
Gear speed selector switch: 1st
Travel speed control dial: 1 on Min.
Servo piston
side 3.0 (+0.2/0) 3.0 0.2
operating pres-
Directional lever: Measure in both for- {31 (+2/0)} {31 2}
sure
ward and reverse position.
Measure while driving at full throttle
(Max. speed: 5 km/h).
Clutch control 45 55C
3.0 (+0.2/0) 3.0 (+0.2/0.1)
Transfer Directional lever: FORWARD
pressure {31 (+2/0)} {31 (+2/1)}
Speed switch: 3rd or 4th speed
Travel at a speed of at least 10 km/h
Steering

20.6 (+1.0/0.5) 20.6 2.0
Steering relief pressure Hydraulic oil temperature:
{210 (+10/5)} {210 20}
45 55C
Flat, horizontal, straight, dry paved road
surface
Speed when applying brake: 35 km/h
Wheel brake
Braking delay: Within 0.1 sec.

Performance Brake pedal operating effort: m Max. 14 Max. 14
322 N {33 kg}
Tire inflation pressure: Specified pres-
sure
Measure braking distance
Disc wear Thickness of lining mm 1 0.1 Max. 0.6
Tire inflation pressure: Specified pres-
Parking brake
sure
Flat paved road with 1/5 (1120') grade
Performance Holds position Holds position
Machine at operating condition
a For measuring posture, see Fig. C and
Fig. D at the end of this section
WA320, 320PZ-6 20-100 5


Work equipment control valve Category
Standard value for

new machine

MPa 20.6 0.4 20.6 2.0
Relief pressure Hydraulic oil temperature:
{kg/cm2} {210 4} {210 20}
45 55C
Engine speed: High idle RAISE 5.7 0.5 Max. 8.6

Lift arm Hydraulic oil temperature: *1
45 55C LOWER 3.5 0.5 Max. 5.3
Steering valve: Neutral
Speed TILT Sec. 1.9 0.3 Max. 2.9
Apply no load *2
Bucket a For measuring posture, see DUMP 1.2 0.3 Max. 1.8
Fig. E Fig. H at the end of
Work equipment
this section TILT *3 1.2 0.3 Max. 2

Bucket no load
Position of work equipment: Lift arm
Lift arm cylinder and bucket in level position Max. 20 Max. 30
Engine stopped
Hydraulic drift mm
45 55C
Stop engine and leave for 5 minutes,
Bucket cylinder then measure for 15 minutes. Max. 17 Max. 26
a For measuring posture, see Fig. J at the
end of this section
Hydraulic drive fan
Max. fan speed Engine coolant temperature: Min. 90C

rpm 1,690 50 1,690 200
Boost temperature: Min. 70C
HST oil temperature: Min. 95C
Engine coolant temperature: Min. 90C MPa 14.7 1.5 14.7 2.3
Fan drive pressure
Boost temperature: Min. 70C {kg/cm2} {150 15} {150 23}
HST oil temperature: Min. 95C
Proximity switch
Clearance between bucket posi-

35
tioner switch
mm
45 55C
Clearance between boom kick-out
35
switch
*1: Time taken to raise bucket from contact with ground (bottom of bucket horizontal) to max. height of lift
arm.
*2: Time taken to move bucket from max. tilt to max. dump.
*3: Time taken to move bucket from horizontal position to max. tilt.
20-100 6 WA320, 320PZ-6

Machine posture and procedure for performance measurement
a Fig. A a Fig. D
a Fig. B a Fig. E
a Fig. C a Fig. F
WA320, 320PZ-6 20-100 7

a Fig. G
a Fig. H
a Fig. J
20-100 8 WA320, 320PZ-6

WA320, 320PZ-6 20-100 9

SEN04184-00

2008 KOMATSU
All Rights Reserved
20-100 10
SEN04185-02
WA320, WA320PZ-6
SEN04185-02
WHEEL LOADER
Shop Manual
WA320-6
WA320PZ-6

WA320-6 70001 and up
30 Testing and adjusting

110 Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting ........................................................................................ 3

Measuring engine speed............................................................................................................................. 8
Measuring exhaust gas color ...................................................................................................................... 10
Adjusting valve clearance ........................................................................................................................... 12
Measuring compression pressure............................................................................................................... 14
Measuring blow-by pressure....................................................................................................................... 17
Measuring engine oil pressure.................................................................................................................... 18
Measuring intake air (boost) pressure ........................................................................................................ 19
Handling fuel system equipment................................................................................................................. 21
Releasing residual pressure in fuel system ................................................................................................ 21
Measuring fuel pressure ............................................................................................................................. 22
Measuring fuel return rate and leakage ...................................................................................................... 24
Bleeding air from fuel circuit........................................................................................................................ 28
Checking leakage in fuel system ................................................................................................................ 29
Handling cylinder cut-out mode operation .................................................................................................. 30
Handling no-injection cranking operation.................................................................................................... 30
Handling controller voltage circuit ............................................................................................................... 31
Check of muffler and muffler stack for looseness and damage .................................................................. 31
Check of muffler function ............................................................................................................................ 32
Check of installed condition of cylinder head and manifolds ...................................................................... 32
WA320, WA320PZ-6 30-110 1

SEN04185-02 Shop Manual
Check of engine piping for damage and looseness .................................................................................... 33

Testing and adjusting air conditioner compressor belt tension ................................................................... 33
Replacing alternator belt ............................................................................................................................. 34
30-110 2 WA320, WA320PZ-6

Tools for testing, adjusting, and troubleshooting SEN04185-02
Tools for testing, adjusting, and troubleshooting
Testing and Sym

Part number Part No. Q'ty Remarks
adjusting item bol
Measuring 1 799-201-9001 Handy smoke checker 1 Bosch index: Level 0 9
A
exhaust gas color 2 Commercially available Smoke meter 1
Adjusting valve 1 795-799 -1131 Gear 1
B
clearance 2 Commercially available Clearance gauge 1
1 795-799-6700 Puller 1 For 107E-1 engine
Measuring com-
C
2 795-502-1590 Gauge assembly 1 0 7 MPa {0 70 kg/cm2}
pression pressure 3 795-790-4410 Adapter 1 For 107E-1 engine
4 6754-11-3130 Gasket 1 For 107E-1 engine
Measuring
D 799-201-1504 Blow-by checker 1 05 kPa {0 500 mmH2O}
blow-by pressure
Pressure gauge: 2.5, 6, 40, 60 MPa
1 799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
Measuring engine
E 2 790-301-1230 Nipple 1
oil pressure
3 799-101-5160 Nipple 1
4 799-40-2320 Gauge 1 Pressure gauge: 1 MPa {10 kg/cm2}
Measuring intake 1 799-10-5002 Hydraulic tester 1
air (boost) pres- F -101 200 kPa {-760 1,500
2 799-201-2202 Boost gauge kit 1
sure mmHg}
799-101-5002 Hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Pressure gauge: 60 MPa {600
790 - 261 - 1204 Digital hydraulic tester 1
Measuring fuel kg/cm2}
compression G 6732-81-3170 Adapter 1 10 1.0 mm o R1/8
pressure 2
6215-81-9710 O-ring 1
3 799-401-2320 Hydraulic tester 1 Pressure gauge:1 MPa {10 kg/cm2}
4 795-790-5110 Screw 1
5 799-201-2202 Boost gauge kit 1
1 795-790-4700 Tester kit 1
2 795-790-6700 Adapter 1
6754-71-5340 Connector 1
Measuring fuel 3
6754-71-5350 Washer 1
return rate and H
4 Commercially available Measuring cylinder 1
leakage
5 Commercially available Stopwatch 1
Hose(Inside diameter: 14
6 Commercially available 1
mm)
Testing accelera-
J 79A-264-0021 Push-pull scale 1 0 300 N {0 30 kg}
tor pedal
Testing directional 1 79A-264-0021 Push-pull scale 1 0 300 N {0 30 kg}
K
lever 2 Commercially available Scale 1
Testing and 799-101-5002 Analog hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
adjusting HST oil L
pressure 790-261-1204 Digital hydraulic tester 1
kg/cm2}
799-101-5002 Analog hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
1
Testing clutch Pressure gauge: 60 MPa {600
M 790-261-1204 Digital hydraulic tester 1
control pressure kg/cm2}
799-401-3200 Adapter 1
2 For hose size #03
02896-11009 O-ring 1
Testing steering
N 79A-264-0021 Push-pull scale 1 0 300 N {0 30 kg}
wheel
Testing and 799-101-5002 Analog hydraulic tester 1
{25, 60, 400, 600 kg/cm2}
adjusting steer- P
ing oil pressure 790-261-1204 Digital hydraulic tester 1
kg/cm2}
WA320, WA320PZ-6 30-110 3

SEN04185-02 Tools for testing, adjusting, and troubleshooting
Testing and Sym

adjusting item bol
1 799-205-2200 Tachometer kit 1 Digital display:6 99999.9 rpm
{25, 60, 400, 600 kg/cm2}
Testing hydraulic 2
Q Pressure gauge: 60 MPa {600
fan 790-261-1204 Digital hydraulic tester 1
kg/cm2}
799-401-3400 Adapter 1
3 For hose size #05
02896-11015 O-ring 1
Testing and Pressure gauge: 2.5, 6, 40, 60 MPa
adjusting accu- {25, 60, 400, 600 kg/cm2}
R
mulator charge Pressure gauge: 60 MP a{600
790-261-1204 Digital hydraulic tester 1
pressure kg/cm2}
1 793-605-1001 Brake test kit 1
2 790-101-1430 Coupler 1
3 790-101-1102 Pump 1
Testing wheel
S 4 790-301-1720 Adapter 1 20 1.5 mm o R1/8
brake oil pressure
5 799-101-5160 Nipple 1
6 799-401-2220 Hose 1 Length: 5 m
7 790-261-1130 Coupling 1
Holding work
equipment posi- T 793-463-1100 Stopper 1
tion
Testing and
adjusting parking
V 79A-264-0021 Push-pull scale 1 0 300 N {0 30 kg}
brake control
cable
Testing work 1 79A-264-0021 Push-pull scale 1 0 300 N {0 30 kg}
W
equipment lever 2 Commercially available Scale 1
adjusting work {25, 60, 400, 600 kg/cm2}
X
equipment oil Pressure gauge: 60 MPa {600
pressure kg/cm2}
adjusting work {25, 60, 400, 600 kg/cm2}
Y
equipment PPC Pressure gauge: 60 MPa {600
oil pressure kg/cm2}
799-601-7400 T-adapter assembly 1 AMP040 Connector
799-601-7500 T-adapter assembly 1 AMP070 Connector
799-601-9000 T-adapter assembly 1 DT, HD30 Connector
799-601-9300 T-adapter assembly 1 DRC26-40 (5 pins)
799-601-7360 Adapter 1 For REL-5P
799-601-7310 T-adapter 1 SWP (12 poles)
Diagnosis for 799-601-7070 T-adapter 1 SWP (16 poles)
799-601-4101 T-adapter assembly 1 Connected with engine
engine related
795-799-5530 q T-adapter 1 Engine coolant temperature
controller, sensor Z
799-601-4230 q T-adapter 1 Boost temperature/pressure sensor
actuator and har-
799-601-4130 q T-adapter 1 Ne sensor, CAM sensor
ness 799-601-4160 q T-adapter 1 Hydraulic pressure sensor
799-601-4211 q T-adapter 1 Controller (50 poles)
799-601-4140 q T-adapter 1 Ambient pressure sensor
799-601-4340 q T-adapter 1 Pump actuator
799-601-4190 q T-adapter 1 Common rail pressure sensor
30-110 4 WA320, WA320PZ-6

Testing and Sym

adjusting item bol
799-601-2500
or
799-601-2700
or
799-601-2800
or T-adapter 1 799-601-2900 is not supplied
799-601-2900
or
799-601-7100
Diagnosis for or
chassis related 799-601-8000
799-601-2600 q T-adapter box 1 Econo (Excl. 799-601-2700)
controller, sensor Z
799-601-2740 q Adapter for MIC 1 For MIC-5P
actuator and har-
799-601-4101 T-adapter assembly 1
ness
799-601-4211 q Adapter for DRC 1 For DRC50
799-601-9020 q Adapter for DT 1 For DT2P
799-601-7000
or
799-601-7100
or T-adapter assembly 1
799-601-7400
or
799-601-8000
WA320, WA320PZ-6 30-110 5

SEN04185-02 Tools for testing, adjusting, and troubleshooting
Testing and Sym

adjusting item bol
799-601-7010 q Adapter for X 1 For X1P
790-601-7050 q Adapter for SWP 1 For SWP6P
799-601-7060 q Adapter for SWP 1 For SWP8P (Excl. 799-601-8000)
For M1P
799-601-7080 q Adapter for M 1 (Excl. 799-601-7000 and
799-601-7100)
799-601-7090 q Adapter for M 1 For M2P
790-601-7150 q Adapter for S 1 For S10P
799-60-7180 q Adapter for AMP040 1 For A8P (799-601-7400 only)
For A12P
799-601-7190 q Adapter for AMP040 1 (Excl. 799-601-7000 and
799-601-7100)
799-601-7330 q Adapter for S 1 For S16PW (799-601-8000 only)
799-601-7320 Adapter for SWP 1 For SW16P
799-601-7340 Adapter for M 1 For M8P
799-601-7360 Adapter for relay 1 For REL-5P
799-601-7370 Adapter for relay 1 For REL-6P
799-601-7520 q Adapter for 070 1 For 070-12P
799-601-7530 q Adapter for 070 1 For 070-14P
Diagnosis for 799-601-7540 q Adapter for 070 1 For 070-18P
chassis related 799-601-7550 q Adapter for 070 1 For 070-20P
controller, sensor Z 799-601-9000
actuator and har- or T-adapter assembly 1
ness 799-601-9200
For DT2P
799-601-9020 q Adapter for DT 1 (Incl. in 799-601-4101 and
799-601-4201)
For DT4P
799-601-9040 q Adapter for DT 1 (Incl. in 799-601-4101 and
799-601-4201)
799-601-9060 q Adapter for DT (Gray) 1 For DT8PGR
q Adapter for DT
799-601-9070 1 For DT8PB
(Black)
q Adapter for DT
799-601-9080 1 For DT8PG
(Green)
799-601-9110 q Adapter for DT (Gray) 1 For DT12PGR
q Adapter for DT
799-601-9120 1 For DT12PB
(Black)
q Adapter for DT
799-601-9130 1 For DT12PG
(Green)
q Adapter for DT
799-601-9140 1 For DT12P
(Brown)
799-601-9350 q Adapter for DRC 1 For DRC-40
799-601-9360 q Adapter for DRC 1 For DRC-24
Multi-adapter for DT24,
799-601-9890 1 For DT2-4, DTM2
DTM2
Measuring cool-
ant and oil tem- 799-101-1502 Digital thermometer 1
perature
Measuring time
Commercially available Stopwatch 1
and speed
30-110 6 WA320, WA320PZ-6

Testing and Sym

adjusting item bol
Measuring volt-
age and resis- Commercially available Tester 1
tance
Removal and
installation of
3.26 mm TORX wrench
boost pressure Commercially available TORX wrench 1
(KTC Q4T15 or equivalent)
and temperature
sensor
19 mm deep socket
(MITOLOY 4ML-19 or equivalent)
Removal and 795T-981-1010 Socket 1
(Appleid engine serial number:
installation of
26530193-)
engine coolant
21 mm deep socket
temperature sen-
(MITOLOY 4ML-21 or equivalent)
sor Commercially available Socket 1
(Appleid engine serial number:
26500006-26530192)
Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketched.
Socket
WA320, WA320PZ-6 30-110 7

SEN04185-02 Measuring engine speed
Measuring engine speed 2. Measuring HST stall speed

1) Referring to Special function of machine
k
monitor, select the real time monitoring
Put chocks under the tires securely.
k
function of the service mode.
When measuring, check that there are no
persons around the machine. 2) Select the two-item simultaneous monitoring
(2 ITEMS) and then enter the following code
a Measure the engine speed under the following numbers directly.
condition. a Monitoring items
q Engine coolant temperature:
[1] Code No.01001: ENG SPEED (Engine
Within operation range speed)
q Hydraulic oil temperature:
[2] Code No.04408: HST OIL TEMP (HST
Within operation range oil temperature)
q HST oil temperature:
Within operation range
1. Measuring engine speed(low idle and high idle)

2) Display ENG SPEED from the monitoring
items of the machine monitor.
a Monitoring item
Code No. 01001: ENG SPEED (Engine
speed)
3) Start the engine.

4) Lower the bucket to near the ground, then
drive the machine forward and thrust the
bucket into the stockpile of soil or rock
(portion a).
3) Start the engine, set it in the measuring

condition, and measure the engine speed.
5) While running the engine at high idle, press

the accelerator pedal gradually. When the
HST stalls, measure the engine speed.
a Measure the stall speed 2 3 times.
a Do not keep stalling the HST for more
than 20 seconds. Take care that the HST
oil temperature will not exceed 120C.
30-110 8 WA320, WA320PZ-6

Measuring engine speed SEN04185-02
3. Measuring hydraulic stall speed 4. Measuring HST stall and hydraulic stall (full stall)
1) Referring to Special function of machine speed
monitor, select the real time monitoring 1) Set the machine monitor as in 2. Measuring
function of the service mode. HST stall speed.
2) Display ENG SPEED from the monitoring 2) Start the engine.
items of the machine monitor. 3) Lower the bucket to near the ground, then
a Monitoring item drive the machine forward and thrust the
Code No. 01001: ENG SPEED (Engine bucket into the stockpile of soil or rock
speed) (portion a).
3) Run the engine at high idle. 4) While running the engine at high idle, stall the
4) Relieve the lift arm cylinder or bucket cylinder HST and relieve the lift arm cylinder or bucket
on the extraction side and measure the cylinder on the extraction side simultane-
engine speed. ously and measure the engine speed at this
a Finish measurement in a short time so time.
that the hydraulic oil temperature will not a Do not keep stalling the HST for more
exceed 120C. than 20 seconds. Take care that the HST
WA320, WA320PZ-6 30-110 9

SEN04185-02 Measuring exhaust gas color
Measuring exhaust gas color 2. Measuring with smoke meter A2

1) Insert the probe of smoke meter A2in the
a Necessary tools
outlet of the muffler (exhaust pipe) and fix it
Symbol Part No. Part Name
1 799-201-9001 Handy smoke checker
to the exhaust pipe with a clip.
A Commercially
2 Smoke meter
available
k When installing and removing the measuring
instruments, take care not to touch a hot
part.
a If an air source and an electric power source are
not available in the field, use handy smoke
checker A1. When recording official data, use
smoke meter A2.
a Measure the exhaust gas color under the follow-
ing condition.
q Engine coolant temperature: Within operat-
ing range
1. Measuring with handy smoke checker A1 2) Connect the probe hose, receptacle of the
1) Stick a sheet of filter paper to smoke checker accelerator switch, and air hose to smoke
A1. meter A2.
2) Insert the exhaust gas intake pipe in the a Keep the pressure of the supplied com-
muffler (exhaust pipe). pressed air at 1.5 MPa {15 kg/cm2}or be-
3) Start the engine and heighten the engine low.
coolant temperature to the operating range. 3) Connect the power cable to a 100 V AC
4) Accelerate the engine suddenly and run it at receptacle.
HST stalling and hydraulic stalling, and a Confirm that the smoke meter power
operate the handle of smoke checker A1 so switch is in the OFF position, before con-
that the filter paper will absorb the exhaust necting the power cable to an outlet.
gas. 4) Loosen the cap nut of the suction pump and
fit the filter paper.
a Fit the filter paper securely so that the ex-
haust gas will not leak.
5) Turn on the power switch of smoke meter A2.
5) Take out the filter paper and compare it with

the attached scale for judgement.
6) Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
30-110 10 WA320, WA320PZ-6

Measuring exhaust gas color SEN04185-02
6) Start the engine and keep it running until the

engine coolant temperature rises to the oper-
ating range.
7) Accelerate the engine suddenly or run it at
high idle and press the accelerator pedal of
smoke meter A2 and collect the exhaust gas
into the filter paper.
8) Put the polluted filter paper on non-polluted
filter paper (more than 10 sheets) in the filter
paper holder, and read the indicated value.
9) After finishing work, remove the used instru-
ments and return the removed parts.
WA320, WA320PZ-6 30-110 11

SEN04185-02 Adjusting valve clearance
Adjusting valve clearance 3. Rotate the crankshaft forward (clockwise, seeing

from the fan) with gear B1 and set wide slit (b) of
a Necessary tools
the rotation sensor ring to projection top (a) of
Symbol Part No. Part name
front cover.
1 795-799 -1131 Gear
B Commercially a Projection top (a) must be within the range of
2 Clearance gauge wide slit (b) when it is seen from the air con-
available
ditioner compressor side.
a Adjust the valve clearance under the following a If you can see the yellow marks (c) of projec-
condition. tion top (a) and the damper periphery, you
q Engine coolant temperature: Normal temper-
may set them to each other.
ature a After the above positioning, the No. 1 cylin-
der or No. 6 cylinder is not at the top dead
1. Remove cylinder head cover (1). For details, see center (TDC). Take care. (The cylinder is at
Disassembly and assembly, Removal and 76 88 before the top dead center.)
installation of cylinder head assembly.
a Removal of the engine hood is unnecessary.
4. Check the movement of the rocker arm of the

2. Remove plate (2) and plug (3) at the bottom of No. 1 cylinder to judge the valve to be adjusted.
the starting motor and insert gear B1.
a If you can move the rocker arms of air intake
valves (IN) with the hand by the valve clear-
ance, adjust the valves marked with Q in the
valve arrangement drawing.
a If you can move the rocker arms of air ex-
haust valves (EX) with the hand by the valve
clearance, adjust the valves marked with q in
the valve arrangement drawing.
a Valve arrangement drawing
30-110 12 WA320, WA320PZ-6

Adjusting valve clearance SEN04185-02
5. Adjust the valve clearance according to the

1) While fixing adjustment screw (10), loosen
locknut (11).
2) Insert clearance gauge B2 in the clearance
between rocker arm (12) and crosshead (13)
and adjust the valve clearance with adjust-
ment screw (10).
a With the clearance gauge inserted, turn
the adjustment screw to a degree that you
can move the clearance gauge lightly.
3) While fixing adjustment screw (10), tighten
locknut (11).
3 Locknut:
24 4 Nm {2.45 0.41 kgm}
a After tightening the locknut, check the
valve clearance again.
6. Rotate the crankshaft forward by 1 turn and set

wide slit (b) to projection top (a) according to
step 3.
7. Adjust the other valve clearances according to

steps 4 and 5.
a If the valves marked with q in the valve ar-
rangement drawing were adjusted in steps 4
and 5, adjust the valves marked with Q.
a If the valves marked with Q in the valve ar-
rangement drawing were adjusted in steps 4
and 5, adjust the valves marked with q.
8. After finishing adjustment, remove the adjusting

tools and return the removed parts.
a Remove gear B1 without fail.
3 Cylinder head cover mounting bolt :
24 4 Nm {2.45 0.41 kgm}
WA320, WA320PZ-6 30-110 13

SEN04185-02 Measuring compression pressure
Measuring compression pressure 4. Loosen injector terminal nut (4) and remove the
terminal from the injector.
a Necessary tools
1 795-799-6700 Puller
5. Set the cylinder to be checked to the compres-
2 795-502-1590 Gauge assembly sion top dead center.
C a How to turn the crankshaft, refer to
3 795-790-4410 Adapter
4 6754-11-3130 Gasket Adjusting valve clearance.
k When measuring the compression pressure, a When the cylinder is at the compression top
take care not to burn yourself on the exhaust dead center, the rocker arm of the cylinder
manifold or muffler or get caught in a rotating can be moved by the valve clearance with the
part. hand.
a Measure the compression pressure after the en-
gine is warmed up. 6. Remove rocker arm assembly (5).
(Engine oil temperature: 40 60C)
1. Remove cylinder head cover (1). For details, see

Disassembly and assembly, Removal and
installation of cylinder head assembly.
2. Disconnect 3 injector wiring harness connectors

(2) and move the wiring harnesses.
7. Remove retainer (6) and fuel inlet connector (7).
8. Remove holder (8).
9. Remove injector (9).

a Using puller C1, remove the injector with im-
pacts of a slide hammer.
a Do not remove the injector by prying its top
3. Disconnect fuel high-pressure tube (3). up.
30-110 14 WA320, WA320PZ-6

Measuring compression pressure SEN04185-02
16. Rotate the engine with the starting motor and

measure the compression pressure.
a Read the gauge when its pointer is stabilized.
17. After finishing measurement, remove the

measuring tools and return the removed parts.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) While matching projection (a) of the injector
to notch (b) of the holder, set the injector to
the cylinder head.
a When setting the injector, direct the
above matching position toward the fuel
10. Fit gasket C4 to the end of adapter C3and insert inlet connector insertion side.
them in the injector mounting portion.
11. Fix adapter C3 with injector holder.

a Tighten the holder mounting bolts alternately.
3 Holder mounting bolt :
8 0.8 Nm {0.8 0.08 kgm}
12. Connect gauge assembly C2 to adapter C3.

a If engine oil is applied thinly to the connecting
parts of the adapter and gauge, air does not
leak easily.
13. Install rocker arm assembly (5).

3 Rocker arm assembly mounting bolt : 2) Tighten injector holder mounting bolts (10) by
36 5 Nm {3.67 0.51 kgm} 3 4 turns.
3) Set fuel inlet connector (7).
14. Adjust the valve clearances. a Push in the fuel inlet connector until the
a See Adjusting valve clearance". O-ring is fitted and the connector clicks.
4) Temporarily tighten retainer (6) of fuel inlet
connector (7).
a Tighten the above retainer in step 6).
3 Retainer:
15 5 Nm {1.5 0.5 kgm}
5) Tighten injector holder mounting bolts (10)
alternately.
3 Holder mounting bolt :
8 0.8 Nm {0.8 0.08 kgm}
15. Referring to Special functions of machine

monitor (EMMS) , set the engine in the no-injec-
tion cranking mode.
k If the engine is not set in the no-injection
cranking mode, it starts during measure-
ment and that is dangerous. Accordingly,
be sure to set the engine in the no-injec-
tion cranking mode.
WA320, WA320PZ-6 30-110 15

110Testingandadjusting, Part 1
SEN04185-02 Measuringcompressionpressure
6) vPermanently tighten retainer (6) of fuel inlet

connector (7).
3 Retainer:
50 5 Nm {5.1 0.51 kgm}
7) Tighten the sleeve nut of the fuel highpres-

sure tube on the head side and then tighten
that on the common rail side.
3 Sleeve nut :
35 3.5 Nm {3.6 0.4 kgm}
8) Connect the injector harness connector.
a After installing the rocker arm assembly,

adjust the valve clearance. For details,
see "Adjusting valve clearance".
3 Rocker arm assembly mounting bolt :
36 5 Nm {3.67 0.51 kgm}
a Tighten the injector terminal nut to the fol-

lowing torque.
3 Terminal nut :
1.5 0.25 Nm {0.15 0.025 kgm}
a Tighten the head cover with the following

torque.
3 Head cover mounting nut :
24 4 Nm{2.45 0.41 kgm}
30-110 16 WA320, WA320PZ-6

Measuring blow-by pressure SEN04185-02
Measuring blow-by pressure 5. While pressing the brake pedal, set the direc-
tional lever or switch to the F (forward) or R
a Necessary tools
(reverse) position.
k Keep pressing the brake pedal securely.
D 799-201-1504 Blow-by checker
a Measure the blow-by pressure under the follow- 6. Press the accelerator pedal gradually to the high
ing condition. idle. While running the engine at HST stalling
q Engine coolant temperature: and hydraulic stalling, measure the blow-by
Within operation range pressure.
q Hydraulic oil temperature: a Do not keep stalling the HST for more than
Within operation range 20 seconds. Take care that the HST oil tem-
q HST oil temperature: perature will not exceed 120C.
Within operation range a Normally, the blow-by pressure should be
measured while the engine is operated at the
1. Stop the engine. Install nozzle [1] and hose [2] of rated output. In the field, however, an ap-
blow-by checker D to blow-by hose (1) and proximate value can be obtained by HST
connect them to gauge [3]. stalling and hydraulic stalling.
a If it is impossible to run the engine at the rat-
ed output or HST stalling and hydraulic stall-
ing, measure while the engine is running at
high idle. The value obtained in this case is
about 80% of the blow-by pressure at the rat-
ed output.
a Precaution for measuring blow-by pressure
The blow-by pressure may vary largely with
the engine condition. If the measured value is
judged abnormal, check for increase of oil
consumption, bad exhaust gas color, deterio-
ration of oil, high deterioration speed of oil,
etc. which are related to the abnormal
a Blow-by hose (1) comes out from the rear left blow-by pressure.
of the engine and its end is fixed to the ma-
chine lower frame.
7. Remove the measurement tool after the

measurement, and make sure that the machine
2. Start the engine and increase the engine coolant is back to normal condition.
temperature to the operating range.
3. Press the left brake pedal securely.
4. Release the parking brake.
WA320, WA320PZ-6 30-110 17

SEN04185-02 Measuring engine oil pressure
Measuring engine oil pressure 4. Start the engine and heighten the coolant
a Necessary tools
1 799-101-5002 Hydraulic tester
5. While running the engine at low idle and high
2 790-301-1230 Nipple idle, measure the oil pressure.
E
3 799-101-5160 Nipple
4 799-401-2320 Gauge
a Measure the engine oil pressure under the fol-
lowing condition.
1. Open the engine left side cover.
2. Remove plug (1) from oil filter head.
6. Remove the measurement tool after the

measurement, and make sure that the machine
is back to normal condition.
3. Install nipples E2 and E3, then connect hydraulic

tester E4 (1 MPa {10 kg/cm2}).
30-110 18 WA320, WA320PZ-6

Measuring intake air (boost) pressure SEN04185-02
Measuring intake air (boost) pres- 2. Measurement with measuring tool

sure 1) Open the engine right side cover.
2) Remove air boost pressure pickup plug (1)
a Necessary tools
(R1/8).
F
2 799-201-2202 Boost gauge kit
k When installing and removing the measuring
instruments, take care not to touch a hot part
of the engine.
k Put chocks under the tires securely.
k When measuring, check that there are no
persons around the machine.
a Measure the intake air pressure (boost pres-
sure) under the following condition.
Within operation range 3) Install elbow [1] in hydraulic tester F1 and
q HST oil temperature: nipple [2] in boost gauge kit F2 and connect
Within operation range pressure gauge [3].
1. Measurement with monitoring function

2) Display CHG PRESS-A in the monitoring
functions of the machine monitor.
a Monitoring item
Code No. 36500: CHG PRESS-A (Boost
pressure)
4) Start the engine and increase the coolant

5) Run the engine at medium or higher speed to
drain the oil from the hose.
a Install the connecting parts of the gauge
and hose about a half and open the
self-seal on the hose side repeatedly, and
the oil will be drained.
a If Pm kit (A) is available, you may drain
the oil by using the oil draining coupling
(790-261-1130) in that kit.
3) Press the accelerator pedal gradually to the
a If the oil is left in the hose, the gauge does
high idle and measure the boost pressure
not work. Accordingly, be sure to drain
when HST stalling and hydraulic stalling.
the oil.
a Do not keep the HST stalled for more that
20 seconds so that the HST oil tempera- 6) Press the left brake pedal securely.
ture will not exceed 120C. 7) Release the parking brake.
8) While pressing the brake pedal, set the direc-
tional lever to the F (forward) or R (reverse)
position.
k Keep pressing the brake pedal secure-
ly.
WA320, WA320PZ-6 30-110 19

SEN04185-02 Measuring intake air (boost) pressure
9) Press the accelerator pedal gradually to the

high idle. While running the engine at high
idle, stall the HST and hydraulic work equip-
ment and measure the intake air pressure
(boost pressure).
a Do not keep stalling the HST for more
than 20 seconds. Take care that the HST
10)Remove the measurement tool after the

measurement, and make sure that the
machine is back to normal condition.
30-110 20 WA320, WA320PZ-6

Handling fuel system equipment SEN04185-02
Handling fuel system equipment Releasing residual pressure in

a Precautions for testing and maintaining fuel sys- fuel system
tem a Pressure is generated in the low-pressure circuit
The common rail fuel injection system (CRI) and high-pressure circuit of the fuel system while
consists of more precise parts than the conven- the engine is running.
tional fuel injection pump and nozzle. If foreign Low-pressure circuit:
matter enters this system, it can cause a trouble. Feed pump Fuel filter Supply pump
When testing and maintaining the fuel system, High-pressure circuit:
take care more than the past. If dust, etc. sticks Supply pump Common rail Injector
to any part, wash that part thoroughly with clean a The pressure in both low-pressure circuit and
fuel. high-pressure circuit lowers to a safety level au-
a Precautions for replacement of fuel filter car- tomatically 30 seconds after the engine is
tridge stopped.
The fuel filter cartridge used must be a genu- a Before the fuel circuit is tested and its parts are
ineKomatsu part. removed, the residual pressure in the fuel circuit
The fuel injection pump and nozzle of the must be released completely. Accordingly, ob-
common rail type fuel injection system (CRI) serve the following.
consist of more precision parts than those used k Before testing the fuel system or removing
for the current pumps and nozzles. This system, its parts, wait at least 30 seconds after stop-
therefore, employs a special filter with highly effi- ping the engine until the residual pressure in
cient filtering performance to prevent mixing of the fuel circuit is released. (Do not start the
foreign substances. Thus, substituting it with a work just after stopping the engine since
non-genuine filter could cause troubles in the there is residual pressure.)
fuel system. It is strictly prohibited to use such
part.
WA320, WA320PZ-6 30-110 21

SEN04185-02 Measuring fuel pressure
Measuring fuel pressure 2) Install adapter G2 and nipple [1] of hydraulic

tester G1 and connect them to oil pressure
a Necessary tools
gauge [2].
a Use the oil pressure gauge of 2.5 MPa
799-101-5002 Hydraulic tester
1 {25 kg/cm2}.
790-261-1204 Digital hydraulic tester
Adapter
6732-81-3170
2 (10 1.0 mm o PT1/8)
G
6215-81-9710 O-ring
4 795-790-5110 Screw
5 799-201-2202 Boost gauge kit
k Put chocks under the tires securely.
k When measuring, check that there are no
persons around the machine.
a Test only the fuel pressure in the low-pressure
circuit from the feed pump through the fuel main
filter to the supply pump and in the return circuit
between the supply pump/common rail/ injector
and fuel tank.
k Since the pressure in the high-pressure cir-
3) Run the engine at low idle and measure the
pressure in the fuel low-pressure circuit.
cuit from the supply pump through the com-
a If the pressure in the fuel low-pressure cir-
mon rail to the fuel injector is very high, it
cuit is in the following range, it is normal.
cannot be measured.
0.3 1.1 MPa
During cranking
1. Measuring pressure in fuel low-pressure {3.1 11.3 kg/cm2}
circuit 0.5 1.3 MPa
1) Remove fuel pressure pickup plug (1) from At low idle
{5.1 13.3 kg/cm2}
the fuel main filter.
k If the engine cannot be started, you
may measure the fuel pressure while
rotating the engine with the starting
motor. Do not rotate for more than 20
seconds continuously, however, for
protection of the starting motor.
4) After finishing measurement, remove the

measuring tools and return the removed
parts.
3 Fuel pressure pickup plug:
10 2 Nm {1 0.2 kgm}
30-110 22 WA320, WA320PZ-6

Measuring fuel pressure SEN04185-02
2. Measuring pressure in fuel return circuit 3. Measuring fuel negative-pressure circuit

1) Remove fuel pressure pickup plug (2) from pressure
the fuel return block. 1) Remove joint bolt (2) of fuel hose (1) between
the prefilter and supply pump.
2) Install nipple [3] of hydraulic tester G1 and

nipple [1] and connect them to hydraulic
tester G3. 2) Connect fuel hose (1) to supply pump (3) by
a Nipple [3]: tool G4 instead of joint bolt (2).
790-301-1181, 07002-11223 a When installing tool G4, fit the gaskets to
both sides of the fuel hose joint.
3 Tool G4:
19.6 29.4 Nm {2.0 3.0 kgm}
3) Connect tool G5 to tool G4.

pressure in the fuel return circuit.
a If the pressure in the fuel return circuit is
in the following range, it is normal.
During cranking Max. 0.02 MPa
At low idle {Max. 0.19 kg/cm2} 4) Run the engine and measure the circuit
k If the engine cannot be started, you negative pressure at high idle.
may measure the fuel pressure while Circuit standard negative pressure:
rotating the engine with the starting Max. 50.7 kPa {380 mmHg}
motor. Do not rotate for more than 20 5) If the negative pressure is higher than the
seconds continuously, however, for standard pressure, the fuel prefilter may be
protection of the starting motor. clogged. In this case, replace the fuel prefilter
4) After finishing measurement, remove the and measure again.
measuring tools and return the removed 6) After finishing measurement, remove the
parts. measuring instruments and return the
3 Fuel pressure pickup plug: removed parts.
24 4 Nm {2.4 0.4 kgm} 3 Joint bolt (2):
19.6 29.4 Nm {2.0 3.0 kgm}
WA320, WA320PZ-6 30-110 23

SEN04185-02 Measuring fuel return rate and leakage
Measuring fuel return rate and

leakage
a Necessary tools
1 795-790-4700 Tester kit
2 795-790-6700 Adapter
6754-71-5340 Connector
3
6754-71-5350 Washer
Commercially
H 4 Measuring cylinder
available
Commercially
5 Stopwatch
available
Commercially
6 Hose (Inside diameter 14 mm)
available
a Prepare receiving pan of about 20 liters to re- 4) Crank the engine for 30 seconds and
ceive the fuel flowing out during measurement. measure the delivery with measuring cylinder
k
H4.
Put chocks under the tires securely. a Adjust the route of the test hose so that it
k When measuring, check that there are no will not slacken and put its end in receiv-
persons around the machine. ing pan.
a Do not crank the engine for more than 30
1. Measuring supply pump delivery seconds to protect the starting motor in
1) Open the engine right side cover. any case other than this measurement.
2) Loosen clamp (1) of supply pump discharge a If the supply pump delivery is in the fol-
tube (2) and disconnect the tube. lowing standard range, it is normal.
At cranking speed (125 rpm) Min. 75 cc
At cranking speed (150 rpm) Min. 90 cc
3) Install test hose H6 to the nipple on the

discharge side of the supply pump.
a Fix the hose with a wire etc.
a Adjust the route of the test hose so that it
will not slacken and put its end in receiv- 5) After finishing measurement, remove the
ing pan. measuring instruments and return the
removed parts.
3 Tube sleeve nut:
35 4 Nm {3.6 0.4 kgm}
3 Clamp mounting bolt:
10 2 Nm {1.0 0.2 kgm}
30-110 24 WA320, WA320PZ-6

Measuring fuel return rate and leakage SEN04185-02
2. Measuring return rate from supply pump 5) Run the engine at low idle and measure the
1) Open the engine right side cover. return rate in 25 seconds with measuring
2) Disconnect return hose (1) from the supply cylinder H4.
pump. a If the return rate from the supply pump is
a The return hose is connected by a quick in the following range, it is normal.
coupler. At low idle Max. 400 cc

may measure the return rate while ro-
tating the engine with the starting mo-
tor. Do not rotate for more than 25
3) Install connector H3 and cap nut [1] of tester

kit H1 to the return hose to stop the fuel from
flowing out.
4) Connect test hose [2] of tester kit H1 to the
supply pump.
a Lay the test hose so that it will not slacken
and put its end in the receiving pan.
parts.
a When measuring the leakage from the
pressure limiter or finishing the measure-
ment: Return the removed parts to their
original positions.
a When measuring the leakage from the in-
jector: Leave the removed parts as they
are and keep the test hose end in the re-
ceiving pan.
WA320, WA320PZ-6 30-110 25

SEN04185-02 Measuring fuel return rate and leakage
3. Measuring leakage from pressure limiter 6) Run the engine at low idle and measure the
1) Open the engine right side cover. leakage in 1 minute with measuring cylinder
2) Remove the main fuel filter bracket mounting H4.
bolt (2), and move the fuel filter and bracket a If the leakage from the pressure limiter is
assembly (3). in the following range, it is normal.
0 cc
At low idle
(No leakage)
3) Disconnect return hose (4) from the pressure

limiter.
a Install the seal washer to the connector
bolt.
parts.
3 Joint bolt:
24 4 Nm {2.4 0.4 kgm}
4. Measuring return rate from injector

a The leakage from the injector is measured
while the return hose of the pressure limiter is
connected. Accordingly, before measuring
the leakage from the injector, check that the
leakage from the pressure limiter is normal.
1) Referring to Measuring return rate from
supply pump, set the supply pump for
4) Install removed connector bolt (5) and cap
measurement.
k The fuel returning from the supply
nut [1] of tester kit H1 to the return hose to
stop the fuel from flowing out.
pump flows out during measurement
5) Install connector H3 to the common rail and
of the return rate from the injector. Ac-
connect test hose [2] of tester kit H1.
cordingly, keep the test hose end in
the receiving pan.
and put its end in the oil (receiving) pan.
2) Remove connector bolt (6) of the return
block.
30-110 26 WA320, WA320PZ-6

Measuring fuel return rate and leakage SEN04185-02
3) Install connector bolt [3] of adapter H2

instead of the removed connector bolt and
connect test hose [4].
and put its end in the receiving pan.

return rate in 1 minute with measuring
cylinder H4.
a If the return rate from the injector is in the
following range, it is normal.
During cranking Max. 90 cc
At low idle Max. 180 cc

may measure the return rate while ro-
tating the engine with the starting mo-
tor. Do not rotate for more than 20

parts.
3 Joint bolt:
24 4 Nm {2.4 0.4 kgm}
WA320, WA320PZ-6 30-110 27

SEN04185-02 Bleeding air from fuel circuit
Bleeding air from fuel circuit

a If fuel is used up or if a fuel circuit part is removed
and installed, bleed air from the fuel circuit ac-
cording to the following procedure.
k Stop the machine on a level ground, lower
the work equipment to the ground, and set
chocks under the tire securely.
1. Fill the fuel tank with fuel.
2. Open the right side cover of the engine.
3. Turn feed pump knob (1) to the left to pull it out

and operate it forward and backward.
a Keep the operation of the knob until becomes
hard to operate.
a The plug at the top of the fuel main filter does
not need to be removed.
4. After bleeding air, push in knob (1) and turn it to

the right to fix it.
30-110 28 WA320, WA320PZ-6

Checking leakage in fuel system SEN04185-02
Checking leakage in fuel system 9. Inspect the fuel piping and devices for fuel
k
leakage.
Very high pressure is generated in the high-
a Check mainly around the high-pressure cir-
pressure circuit of the fuel system. If fuel
cuit parts coated with the color checker for
leaks while the engine is running, it is dan-
fuel leakage.
gerous since it can catch fire.
a If fuel leakage is recognized, repeat the pro-
After testing the fuel system or removing its
cedure from step 1 after repairing the leak-
parts, check it for fuel leakage according to
age.
the following procedure.
a If no fuel leakage is detected, check is com-
a Clean and degrease the engine and the parts
pleted.
around it in advance so that you can test it easily
for fuel leakage.
1. Spray color checker (developer) over the fuel

supply pump, common rail, fuel injector, and
joints of the high-pressure piping.
2. Run the engine at speed below 1,000 rpm and

stop it after its speed is stabilized.
3. Inspect the fuel piping and devices for fuel

leakage.
fuel leakage.
age.
4. Run the engine at low idle.

leakage.
fuel leakage.
age.
6. Run the engine at high idle.

leakage.
fuel leakage.
age.
8. Start the engine and stall the HST or relieve the

hydraulic pump to apply some load on the
engine.
WA320, WA320PZ-6 30-110 29

SEN04185-02 Handling cylinder cut-out mode operation
Handling cylinder cut-out mode Handling no-injection cranking

operation operation
a Cylinder cut-out mode operation means to run a No-injection cranking means to crank the engine
the engine with the fuel injectors of 1 or more cyl- with the starting motor while all the injections are
inders disabled electrically to reduce the number stopped electrically. The purpose and effect of
of effective cylinders. The purposes and effects this operation are as follows.
of this operation are as follows. q When a machine or engine has been stored for
a long time, implementing the no-injection crank-
1. This operation is used to find out a cylinder ing before starting the engine lubricates the en-
which does not output power normally (or, gine parts and thus prevents its seizure.
combustion in it is abnormal). a The no-injection cranking operation is set from
the service mode of the machine monitor. For
2. When a cylinder is selected for the cylinder details, see Special functions of machine mon-
cut-out mode operation, if the engine speed and itor (EMMS), No-injection cranking function.
output do not change from the normal operation
(all-cylinder operation), that cylinder has 1 or
more defects. The possible defects are as
follows.
q Compression leakage through cylinder head
gasket
q Defective injection
q Defective piston, piston ring, or cylinder liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system

controls the injector of each cylinder electroni-
cally, the operator can perform the reduced
cylinder mode operation easily with switches to
find out a defective cylinder.
a The reduced cylinder mode operation is set
from the service mode of the machine moni-
tor.
For details, see Special functions of
machine monitor (EMMS), Cylinder cutout
mode operation function.
30-110 30 WA320, WA320PZ-6

Handling controller voltage circuit SEN04185-02
Handling controller voltage circuit Check of muffler and muffler stack

1. When disconnecting or connecting a connector for looseness and damage
between the engine controller and engine, be 1. Check the muffler and muffler stack visually for a
sure to turn the starting switch OFF. crack and damage. If any part is damaged,
replace it.
2. If a T-adapter is inserted in or connected to a
connector between the engine controller and 2. Check the mounting bolts and nuts of the muffler
engine for troubleshooting, do not start the and muffler stack for looseness. If they are loos-
engine. ened, retighten them.
a You may turn the starting switch to the OFF
or ON position but must not turn it to the
START position.
WA320, WA320PZ-6 30-110 31

SEN04185-02 Check of muffler function
Check of muffler function Check of installed condition of

q Check the muffler for abnormal sound and differ- cylinder head and manifolds
ence in sound from a new machine. If it makes Check the installed condition of the cylinder head
abnormal sound, repair it, referring to the Trou- and air intake manifold and exhaust manifold. If they
bleshooting Volume. are loosened, retighten them.
a For the tightening torque, see the "Disassembly
and assembly" volume.
30-110 32 WA320, WA320PZ-6

Check of engine piping for damage and looseness SEN04185-02
Check of engine piping for Testing and adjusting air condi-

damage and looseness tioner compressor belt tension
Air intake and exhaust systems:
Check the piping for damage, looseness of the Testing
mounting bolts and nuts, and suction of air and q Press the middle point between air conditioner
leakage of exhaust gas through the joints. If it is compressor pulley and drive pulley with a finger
loosened or damaged, retighten or repair. and measure deflection (a) of the belt.
a Pressing force: Approx. 98 N {Approx. 10 kg}
Cooling system: a Standard deflection (a): 11 14.5 mm
Check the piping for damage, looseness of the
mounting bolts and nuts, and leakage of water
through the joints. If it is loosened or damaged,
retighten or repair.
Fuel system:
Check the piping for damage, looseness of the
mounting bolts and nuts, and leakage of fuel
through the joints. If it is loosened or damaged,
retighten or repair.
Adjusting
a If the deflection is abnormal, adjust it according
to the following procedure.
1. Loosen compressor bracket upper mounting

bolts (1) and lower fixing nut (2).
2. Loosen locknut (3) and adjust the belt tension by

turning adjustment bolt (4).
3. After the tension is adjusted to the reference

value, tighten locknut (3), fixing nut (2) and
compressor bracket mounting bolts (1).
WA320, WA320PZ-6 30-110 33

SEN04185-02 Replacing alternator belt
Replacing alternator belt

a The auto-tensioner is provided for the alternator
belt. Thus, testing and adjustment of the belt is
usually no necessary.
a Remove air conditioner compressor belt before
replacing the alternator belt.
k Stop the machine on a flat ground and lower
the work equipment to the ground.
1. Open the engine left side cover.
2. Apply wrench (a) to part A (width across flats T

12.7 mm) of tensioner assembly (1) and turn it in
the arrow direction to decrease the tension of fan
belt (2).
k Make sure that the wrench (a) is secured
at portion (A) before rotating it. (The
spring of tensioner assembly (1) is
strong. If the wrench is loosely inserted,
the wrench may accidentally come off
while being rotated and it is extremely
dangerous.)
k After removing alternator belt (2), return
tensioner assembly (1) slowly with care.
k Be careful not to get your fingers caught
between the pulley and alternator belt (2)
during work.
3. Replace alternator belt (2).

q Check each pulley for breakage and crack.
30-110 34 WA320, WA320PZ-6

Replacing alternator belt SEN04185-02
WA320, WA320PZ-6 30-110 35

SEN04185-02
2009 KOMATSU
All Rights Reserved
30-110 36
SEN04186-03
WA320-6
WA320PZ-6
WA320-6 70001 and up

30 Testing and adjusting 30

Checking operating force of accelerator pedal ............................................................................................... 3
Checking directional lever............................................................................................................................... 4
Testing and adjusting HST oil pressure .......................................................................................................... 5
Testing clutch control pressure ....................................................................................................................... 9
Testing and adjusting steering wheel ............................................................................................................ 10
Testing and adjusting steering oil pressure................................................................................................... 12
Bleeding air from steering circuit................................................................................................................... 14
Testing hydraulic fan ..................................................................................................................................... 15
Measuring brake pedal ................................................................................................................................. 17
Testing and adjusting brake pedal linkage .................................................................................................... 18
Measuring brake performance ...................................................................................................................... 19
Testing and adjusting accumulator charge pressure..................................................................................... 20
Testing wheel brake oil pressure................................................................................................................... 22
Testing wear of brake disc ............................................................................................................................ 25
Bleeding air from wheel brake circuit ............................................................................................................ 26
Releasing residual pressure in brake accumulator circuit............................................................................. 27
Testing parking brake performance............................................................................................................... 28
Testing and adjusting parking brake control cable ........................................................................................ 29
Measuring and adjusting work equipment control lever................................................................................ 30
Testing and adjusting work equipment hydraulic pressure ........................................................................... 31
Testing work equipment PPC oil pressure .................................................................................................... 32
Bleeding air from hydraulic circuit ................................................................................................................. 34
Releasing remaining pressure in hydraulic circuit......................................................................................... 35
WA320-6 WA320PZ-6 30-120 1

SEN04186-03
Testing and adjusting bucket positioner ........................................................................................................ 36

Testing and adjusting of boom kick-out switch .............................................................................................. 37
Checking proximity switch operation pilot lamp ............................................................................................ 38
Procedure for testing diodes ......................................................................................................................... 39
Preparation work for troubleshooting for electric system .............................................................................. 40
Starting KOMTRAX terminal operations........................................................................................................ 44
Indicator lamps of KOMTRAX terminal ......................................................................................................... 48
30-120 2 WA320-6 WA320PZ-6

Checking operating force of accelerator pedal SEN04186-03
Checking operating force of a After greasing, wipe off grease completely (No
accelerator pedal 1
grease is adhered on roller surface and roller
sliding surface).
Necessary tools
J 79A-264-0021 Push-pull scale

Testing accelerator pedal operating effort
1. Set push-pull scale J at a position 150 mm

from pedal fulcrum (a).
a Put the center of push-pull scale J in con-
tact with a point 150 mm from the pedal 5. After finishing the work, remove the measuring
fulcrum. instruments and return the removed parts.
Testing accelerator pedal operating angle
1. Start the engine.

2. Measure operating angle () when the pedal is
operated from the low idle position to the high
idle position.
3. Apply angle gauge [1] to accelerator pedal (1)
and measure pressing angle between low idle
angle 1 and high idle angle 2 ( = 1 2).
2. Start the engine, then measure the maximum

value when the pedal is pushed in from the low
idle position to the end of its travel (high idle).
3. Stop the engine.
4. If the squeak noise is heard from accelerator
pedal when checking, lubricate from grease
nipple (1) of roller shaft.
2 Roller shaft: Grease (G2-LI)
WA320-6 WA320PZ-6 30-120 3

SEN04186-03 Checking directional lever
Checking directional lever 1
Necessary tools
1 79A-264-0021 Push-pull scale
K Commercially
2 Scale
available

Checking operating effort of directional lever
1. Stop the engine.

2. Install push-pull scale K1 or a spring balance
to a point 10 mm from the tip of the directional
lever, then measure the operating effort when
the lever is pulled in the direction of actuation.
a Carry out the measurement in each speed
range.
Checking travel of directional lever
1. Stop the engine.

2. Make mark (a) on the center of the knob of the
directional lever, then measure the travel with
scale K2 when the lever is operated in the
direction of actuation.
30-120 4 WA320-6 WA320PZ-6

Testing and adjusting HST oil pressure SEN04186-03
Testing and adjusting HST oil

pressure 1
Necessary tools
799-101-5002 Analog type hydraulic tester
L
790-261-1204 Digital type hydraulic tester
k Loosen the oil filler cap slowly to release

the pressure inside the hydraulic tank.
a HST oil temperature when measuring: Within
operating range
a The high-pressure relief pressure is the same
as the safety pressure of the main circuit, so it 3. Measure the high-pressure cut-off oil pressure
cannot be measured. (Normally, the cut-off under the following conditions.
valve is actuated first, so it does not rise to the 1) Lower the bucket to near the ground, then
safety valve set pressure) drive the machine forward and thrust the
bucket into the stockpile of soil or rock
Testing (portion a).
a Set the directional lever to FOR-
Testing high-pressure cut-off oil pressure WARD and the speed selector switch
[Testing with monitoring function] to 2nd and traction control switch to
1. Referring to Special functions of machine ON.
monitor (EMMS), select the real-time monitor-
ing function in the service mode.
2. Display HST PRESS among the monitoring
items of the machine monitor.
a Monitoring item
Code No. 32600: HST PRESS (HST oil
pressure)
[Testing with tools]
1. Open the engine hood side cover.
2. Install oil pressure gauge L (60 MPa {600 kg/
cm2}) to pressure measurement nipple (1).
q Nipple (1): For FORWARD circuit
(port: MA)
q Nipple (2): For REVERSE circuit
(port: MB) 2) Run the engine at full throttle and press
a Install the oil pressure gauge L to nip- the bucket into part a until the machine
ple (1) of the forward circuit. does not move forward.
k Carry out the measurement on
hard ground where it is difficult for
the tires to slip.
3) Keep the engine running at full throttle,
check that the tires are not turning, then
measure the oil pressure.
4) After finishing the work, remove the mea-
suring instruments and return the
removed parts.
WA320-6 WA320PZ-6 30-120 5

SEN04186-03 Testing and adjusting HST oil pressure
Testing low-pressure relief pressure (basic 2. Remove servo piston control pressure mea-
pressure of work equipment PPC circuit) surement plug (5) (DA pressure) (10 mm, P =
[Testing with monitoring function] 1.25 mm).
See Testing high-pressure cut-off oil pressure.
[Testing with tools]
1. Remove low-pressure relief pressure mea-
surement plug (3) (10 mm, P = 1.25 mm) from
under the machine.
a The oil pressure pickup plug is installed to
the accumulator bottom near the lower
right of the transfer on the right side of the
rear frame.
2. Install a nipple, then connect oil pressure

gauge L (6 MPa {60 kg/cm2}).
3. Install nipple L [3], then connect oil pressure

gauge L [1], L [2] (6 MPa {60 kg/cm2}).
3. Place the directional lever at N, run the engine

at high idle, and measure the low-pressure
relief pressure.
4. After finishing the work, remove the measuring
instruments and return the removed parts. 4. Place the directional lever at N, run the engine
at high idle, and measure the control pressure
Testing servo piston control pressure (DA pres- when the brake pedal is depressed and when it
sure) is released.
a The brake pedal is connected to the inch-
1. Remove floor frame cover (4) (bottom left of
ing valve and controls the control pres-
operator's cab).
sure.
instruments and return the removed parts.
30-120 6 WA320-6 WA320PZ-6

Testing and adjusting HST oil pressure SEN04186-03
Testing servo piston actuating pressure Adjusting

1. Remove servo piston actuation pressure mea-
surement plug (6) or (7) (G 1/4) (width across a The high-pressure relief pressure is also the
flats for hexagonal head wrench: 8 mm). safety pressure of the main circuit, so it cannot
q Plug (6): For FORWARD circuit (port: X1) be measured. (Normally, the cut-off valve is
q Plug (7): For REVERSE circuit (port: X2) actuated first, so it does not rise to the safety
valve set pressure)
Adjusting high-pressure cut-off valve
a If the high-pressure cut-off pressure is not cor-
rect, adjust high-pressure cut-off valve (8) as
follows.
1. Remove the engine hood.
2. Loosen locknut (9) of high-pressure cut-off
valve (8), then turn adjustment screw (10) to
adjust.
a Turn the adjustment screw to adjust as fol-
lows.
q To INCREASE pressure, turn
CLOCKWISE.
q To DECREASE pressure, turn
2. Install a nipple L [3], then connect oil pressure COUNTERCLOCKWISE.
gauge L [1], L [2] (6 MPa {60 kg/cm2}). a Amount of adjustment for one turn of
adjustment screw: 9.1 MPa {93 kg/cm2}
3. After adjusting, tighten locknut (9).
3 Locknut: 37.2 Nm {3.8 kgm}
3. Measure the servo piston actuating pressure

under the following conditions.
1) Set the gear speed selector switch in the
1st position and set the travel speed
control dial in the 1 position on the low-
est speed side.
2) Measure the oil pressure while driving for-
ward at full throttle (5 km/h). Similarly,
measure while driving in reverse.
a Do not press the brake pedal.
a After completion of adjustment, repeat the

measurement procedure to check the
high-pressure cut-off oil pressure again.
WA320-6 WA320PZ-6 30-120 7

SEN04186-03 Testing and adjusting HST oil pressure
Adjusting low-pressure relief valve Adjusting DA valve

a If the low-pressure relief pressure is not cor- a If the servo piston control pressure is not cor-
rect, adjust the low-pressure relief valve as fol- rect, adjust the DA valve as follows.
lows. 1. Remove the engine hood.
1. Remove the engine hood. 2. Loosen locknut (16) of DA valve (15), then turn
2. Remove cap (12) and loosen low-pressure adjustment screw (17) to adjust.
relief valve (11) and locknut (13) and rotate a Turn the adjustment screw to adjust as fol-
adjustment screw (14) to adjust the pressure. lows.
a Turn the adjustment screw to adjust as fol- q To DECREASE pressure, turn
lows. CLOCKWISE.
q To INCREASE pressure, turn q To INCREASE pressure, turn
CLOCKWISE. COUNTERCLOCKWISE
q To DECREASE pressure, turn a Amount of adjustment for one turn of
COUNTERCLOCKWISE adjustment screw: 0.34 MPa {3.5 kg/cm2}
a Amount of adjustment for one turn of 3. After adjusting, tighten locknut (16).
adjustment screw: 0.38 MPa {3.9 kg/cm2} 3 Locknut: 64.7 Nm {6.6 kgm}
3 Locknut: 69.6 Nm {7.1 kgm}

measurement procedure to check the con-
a After completion of adjustment, repeat the trol pressure again.
measurement procedure to check the low-
pressure relief pressure again.
30-120 8 WA320-6 WA320PZ-6

Testing clutch control pressure SEN04186-03
Testing clutch control pressure 1 3. Connect hydraulic tester M1 (6 MPa {60 kg/cm2})
and adapter M2 (Hose size: For # 03).
Necessary tools
1
M
799-401-3200 Adapter
2
02896-11009 O-ring
k When removing the measurement plug and

disconnecting the hose, loosen the oil filler
cap slowly to release the pressure inside
the hydraulic tank.
1. Remove the rear frame left side cover (1).
4. Set the speed selector switch to 3rd or 4th,

2. Disconnect clutch solenoid valve output pres- travel at a speed of at least 10 km/h, and mea-
sure (clutch inlet pressure) hose (2). sure the clutch inlet pressure (clutch solenoid
valve output pressure).

WA320-6 WA320PZ-6 30-120 9

SEN04186-03 Testing and adjusting steering wheel
Testing and adjusting steering Measuring operating effort of steering wheel

wheel 1
a Measurement conditions
Necessary tools q Road surface:
Symbol Part No. Part Name Flat, horizontal, dry paved surface
N 79A-264-0021 Push-pull scale
Within green range on engine coolant
temperature gauge
Measuring play of steering wheel q Hydraulic oil temperature:
45 55C
a Measurement conditions q Tire inflation pressure:
q Engine speed: Stopped Specified pressure
q Machine posture: Facing straight forward q Engine speed:
Low idle (bucket empty)
1. Move the steering wheel (1) 2 or 3 times lightly
to the left and right, check that the steering 1. Install push-pull scale N to the steering wheel
mechanism is at the neutral position, then knob (2).
make mark (A) on the outside frame of the
machine monitor. 2. Start the engine.
2. Turn the steering wheel to the right, and make a After starting the engine, raise the bucket
mark (B) at the position where the operating approx. 400 mm and remove the frame
effort starts to become heavy. lock bar.
3. Pull push-pull scale N in the tangential direc-

tion and measure the value when the steering
wheel moves smoothly.
a Do not use the value when the steering
wheel starts to move.
3. Turn the steering wheel to the left in the oppo-

site direction from Step 2, and make mark (C)
a t t h e p o i n t w h e r e t h e o p e r a t i n g e ff o r t
becomes heavy (when the steering valve lever
starts to move). Then measure the distance in
a straight line between marks (B) and (C).
30-120 10 WA320-6 WA320PZ-6

Testing and adjusting steering wheel SEN04186-03
Measuring operating time for steering wheel
q Road surface:
Flat, horizontal, dry paved surface
Within green range on engine coolant
temperature gauge
45 55C
q Tire inflation pressure:
Specified pressure
q Engine speed
Low idle and high idle

a After starting the engine, raise the bucket
approx. 400 mm and remove the frame
lock bar.
2. Operate the steering wheel to the end of its
stroke to turn the machine to the left or right.
3. Measure the time taken to operate the steering
wheel to the end of the stroke to the right or
left.
a Turn the steering wheel smoothly at a
speed of 60 rpm.
a Carry out the measurements both at low
idle and high idle, and to both the left and
right.
WA320-6 WA320PZ-6 30-120 11

SEN04186-03 Testing and adjusting steering oil pressure
Testing and adjusting steering oil 3. Fit a nipple P [3] to the steering circuit pressure
pressure 1
measurement plug hole, then install oil pressure
gauge P [1] and P [2] (40 MPa {400 kg/cm2}).
Necessary tools
P
a Measuring condition
q Hydraulic oil temperature:45 55C
q Engine speed: High idle
Measuring main relief pressure
1. Fit frame lock bar (1) between front frame and

rear frame.
4. Start the engine, run the engine at high idle,
then turn the steering wheel to the left or right
and measure the pressure when the relief
valve is actuated.
2. Remove oil pressure pickup plug (2) of the

steering cylinder circuit.
30-120 12 WA320-6 WA320PZ-6

Testing and adjusting steering oil pressure SEN04186-03
Adjusting main relief pressure 4. Loosen lock screw (5), and then turn adjust-
ment screw (6) to adjust.
1. Stop the engine. a Turn the adjustment screw to adjust as fol-
2. Remove cover (1) at the lower right of the lows.
operator's cab. q To INCREASE pressure, turn
CLOCKWISE.
q To DECREASE pressure, turn
COUNTERCLOCKWISE.
a Pressure adjustment for one turn of
adjustment screw: Approx. 6.9 MPa {70
kg/cm2}
a Tool [1] for adjusting adjustment screw:
Size 7/32 inch, hexagonal
a Do not carry out any adjustment if the
relief pressure cannot be measured accu-
rately.
3 Adjustment screw (6):
2.3 6.8 Nm {0.23 0.69 kgm}
3 Lock screw (5):
3. Disconnect hose (3) and fitting (4) connected 14.7 2 Nm {1.5 0.2 kgm}
to port (T) of the priority valve (2).

WA320-6 WA320PZ-6 30-120 13

SEN04186-03 Bleeding air from steering circuit
Bleeding air from steering circuit 1

a Bleed the air from the circuit as follows if the
steering valve or steering cylinder have been
removed and installed again.
1. Start the engine and run at idle for approx. 5

minutes.
2. Run the engine at low idle and turn 4 5 times

to the left and right.
a Operate the piston rod to approx. 100 mm
before the end of its stroke. Be careful not
to relieve the circuit.
3. Repeat Step 2 with the engine at full throttle.
4. Run the engine at low idle and operate the pis-

ton to the end of its stroke to relieve the circuit.
30-120 14 WA320-6 WA320PZ-6

Testing hydraulic fan SEN04186-03
Testing hydraulic fan 1 3. Connect the cable of probe [2] to tachometer

[4].
Necessary tools
Symbol Part No. Part Name Tachometer kit Q1
1 799-205-1100 Tachometer KIT
2
Q 790-261-1204 Digital type hydraulic tester
799-401-3400 Adapter
3
02896-11015 O-ring

k When removing the measurement plug and
disconnecting the hose, loosen the oil filler
cap slowly to release the pressure inside
the hydraulic tank.
a Measurement conditions 4. Start the engine, run at high idle, and measure
q Hydraulic oil temperature: 45 55C the fan speed.
a Test the fan in a place where the fan blade and
probe will not be exposed to direct sunlight or 5. After finishing the work, remove the measuring
strong light. instruments and return the removed parts.
Testing fan speed
1. Open the radiator grille.
2. Install stand [1], probe [2], and reflecting tape

[3] in the tachometer kit Q1.
WA320-6 WA320PZ-6 30-120 15

SEN04186-03 Testing hydraulic fan
Testing fan drive oil pressure
1. Open the radiator grille.
2. Remove the fan motor cover (1).
4. Start the engine and measure the fan drive oil

pressure.

3. Disconnect hose (2), install oil pressure gauge

Q2 (40 MPa {400 kg/cm 2 }) and adapter Q3
(Hose size: For #04), and connect hose (2)
again.
30-120 16 WA320-6 WA320PZ-6

Measuring brake pedal SEN04186-03
Measuring brake pedal 1
q Engine coolant temperature: Within green
range on engine coolant temperature gauge
q Engine speed: Low idle
1. Install push gauge [1] to the operator's foot.

a Set the push gauge at a point 150 mm
from the fulcrum of the pedal.
2. Start the engine, and measure pedal angle

1 when running at low idle.
3. Apply angle gauge [2] to the brake pedal and

measure pressing angle () between pressing
angles (1) and (2) ( = 1 2).
q Operating effort at (2): 196 N {20 kg}.
WA320-6 WA320PZ-6 30-120 17

SEN04186-03 Testing and adjusting brake pedal linkage
Testing and adjusting brake pedal

linkage 1
Testing
1. Check for play in linkage mounting pin (7), pin-

hole of lever (6), and lever bushing.
2. Measure length of link (1), and check that it is

within the standard value.
Standard link length (a): 184 mm
a Measure the length from the center of pin
(5) to the center of ball joint (3).
3. Measure the distance of movement of rod (8)

and check that clearance (b) is within the stan-
dard value.
Standard clearance (b): 0 0.3 mm
a When doing this, check that the brake
pedal is in contact with the stopper.
Adjusting
Adjusting link length (a)

1. Remove pin (5) and ball joint (3), then remove
rod (1).
2. Loosen locknut (4), then turn yoke (2) and ball
joint (3) to adjust the length.
3. After adjusting the length of link (a), connect it
to the brake pedal.
a Standard value (a): 184 mm
Adjusting clearance (b)

1. Loosen locknut (7), turn rod (8) so that the tip
of the rod contacts the booster cylinder piston,
then turn rod (8) back 1/4 turn.
2. Tighten locknut (7).
a Standard value (b): 0 0.3 mm
30-120 18 WA320-6 WA320PZ-6

Measuring brake performance SEN04186-03
Measuring brake performance 1
9JF01100
q Road surface:
Flat, horizontal, dry paved surface
q Travel speed:
35 km/h when brakes are applied
q Tire inflation pressure:
Specified pressure
q Tire size:
20.5 25
q Delay in applying brakes:
0.1 sec
q Specified operating effort:
322 N {33 kg}
Measurement method
1. Start the engine and drive the machine.
2. Set the speed selector switch to 4th and drive

the machine.
3. When the travel speed reaches 35 km/h,

depress the left brake pedal with the specified
operating effort.
a Before carrying out this operation, deter-
mine the run-up path and the point for
applying the brakes, then apply the brakes
when the machine reaches that point.
4. Measure the distance from the point where the

brakes were applied to the point where the
machine stopped.
a Repeat this measurement three times and
take the average.
WA320-6 WA320PZ-6 30-120 19

SEN04186-03 Testing and adjusting accumulator charge pressure
Testing and adjusting

accumulator charge pressure 1
Necessary tools
R

Measuring
4. Measure the accumulator charge cut-in pres-
q Hydraulic oil temperature: 45 55C sure. Start the engine, run the engine at low
k Stop the engine, then depress the brake idle, and measure the oil pressure when the
pedal at least 100 times to release the pres- brake pressure caution lamp on the monitor
sure inside the accumulator circuit. panel goes out.
q Cut-in pressure:
1. Remove the rear frame left side cover (1). 5.9 +0.2 +2
0 MPa {60 0 kg/cm }
2
5. Measure the accumulator charge cut-out pres-

sure.
a After the accumulator charge cut-in is
actuated, measure the oil pressure when
the indicator of the oil pressure gauge has
risen and suddenly starts to drop.
q Cut-out pressure:
9.8 +0.98
0 MPa {100 +100 kg/cm }
2

2. Remove plug (2).
3. Install measurement nipple and oil pressure

gauge R (40 MPa {400 kg/cm2}).
30-120 20 WA320-6 WA320PZ-6

Testing and adjusting accumulator charge pressure SEN04186-03
Adjusting
a When the accumulator charge cut-out pres-

sure is adjusted, the cut-in pressure also
changes in proportion to the ratio of the valve
area.
1. Loosen locknut (4) of unload relief valve (accu-

mulator charge cut-out valve) (3), then turn
adjustment screw (5) to adjust.
a Turn the adjustment screw to adjust as fol-
lows.
q To RAISE pressure, turn CLOCK-
WISE
q To LOWER pressure, turn COUN-
TERCLOCKWISE
adjustment screw: 1.45 MPa {14.8 kg/cm2}

3 Locknut: 11.8 16.7 Nm {1.2 1.7 kgm}

measurement procedure given above to
check the accumulator cut-in pressure
and cutout pressure again.
WA320-6 WA320PZ-6 30-120 21

SEN04186-03 Testing wheel brake oil pressure
Testing wheel brake oil pressure 1 2. Remove brake tube (2) of the measured side.
a The right side is shown as an example in
a Necessary tools the figure.
3. Remove union (3) and install adapter S4 and
1 793-605-1001 Brake test kit
nipple S5.
2 790-101-1430 Coupler a Use the O-ring fitted to the union.
3 790-101-1102 Pump
S 4 790-301-1720 Adapter
5 799-101-5160 Nipple
6 799-401-2220 Hose
7 790-261-1130 Coupling
T 793-463-1100 Stopper

k Apply the parking brake.
a Measure the oil pressure of the front brakes
(right and left) and rear brakes (right and left)
similarly.
a Measuring condition.
q Engine coolant temperature: Within oper-
ating range
q Hydraulic oil temperature: Within operat-
ing range
1. Remove front frame inspection cover (1).

k When raising the lift arm to remove the
inspection cover, place a stand [1]
under it to support securely.
Instead, you may set stopper T to the
lift arm cylinder to prevent the work
equipment from lowering. 4. Connect brake test kit S1 to nipple S5.
a For the composition and connection, see
the figure on the following page.
5. Connect hose [1] and loosen bleeder screw (4)

to bleed air.
a Operate tool S3 to bleed air.
30-120 22 WA320-6 WA320PZ-6

Testing wheel brake oil pressure SEN04186-03
Composition and connection diagram of brake test kit S
WA320-6 WA320PZ-6 30-120 23

SEN04186-03 Testing wheel brake oil pressure
6. Tighten bleeder screw (4), operate pump S3 to

increase the pressure to 4.1 MPa {42 kg/cm2},
and tighten stop valve [2] (a component part of
S1).
7. Leave the brake circuit pressurized for 5 min-

utes and check lowering of the pressure.
a If the hose is moved while the pressure is
m easure d , t h e p re s s u re f l u c t u at es.
Accordingly, do not move the hose.
a After testing the pressure, operate pump
S3 to lower the pressure in brake test kit
S1, and then remove brake test kit S1.
a After finishing testing, install the brake
tube and bleed air from the brake circuit.

30-120 24 WA320-6 WA320PZ-6

Testing wear of brake disc SEN04186-03
Testing wear of brake disc 1 2. Press the brake pedal to the stroke end.
3. With shaft (2) pushed in, measure projection

k Stop the machine on a level ground, lower (x) from surface (a) of guide (3) (wear).
the work equipment to the ground, and set a Keep pressing the brake pedal while mea-
chocks under the tire securely. suring the wear.
a There are caps for inspection on the right and a If shaft (2) is projected from the end of
left sides of the front and rear axles. Check at guide (3) to the groove, replace the disc.
all of the 4 caps similarly. q Wear: (x) from (a)
q Wear limit: (y) from (a) (1.6 mm)
1. Remove cap (1) from the axle housing. a If surface (b) of shaft is seen, it is wear
limit.
4. After testing, return cap (1).

3 Cap (1): 29.4 39.2 Nm {3.0 4.0 kgm}
WA320-6 WA320PZ-6 30-120 25

SEN04186-03 Bleeding air from wheel brake circuit
Bleeding air from wheel brake 3. Connect hose [1] to bleeder screw (2) and
circuit 1
place hose [1] in the oil receive pan.
a Work on the rear side similarly from under-
Necessary tools side of the machine.
T 793-463-1100 Stopper

a If a brake circuit part is removed and installed,
bleed air from the brake circuit according to the
a Bleed air from the front brake circuit and rear
brake circuit similarly (2 places each).
a When a complete bleeding is required, it is
advisable to start the operation from the brake
cylinder situated farthest from the brake pedal. 4. Press the brake pedal and then loosen bleeder
a The work on the front right side is shown as an screw (2) to bleed air.
example. Work on each brake cylinder simi- a Return the brake pedal slowly after tight-
larly. ening bleeder screw (2).
1. Start the engine to accumulate pressure in the 5. Repeat this operation until the oil flowing
accumulator and then stop the engine. through hose [1] becomes free from bubbles.
Then press the pedal fully and tighten bleeder
2. Remove front frame inspection cover (1). screw (2) while the oil is flowing.
k When raising the lift arm and removing a As accumulated pressure in the accumu-
the inspection cover, place support lator is decreased, start the engine to
stand [1] under the lift arm to support accumulate pressure in the accumulator.
the lift arm securely or set stopper T to Then bleed air using the same procedure
the lift arm cylinder to prevent the work as described above.
equipment from falling. a After finishing bleeding air, run the engine
at low idle and check the oil level in the
hydraulic tank. If the level is low, add oil up
to the specified level.

30-120 26 WA320-6 WA320PZ-6

Releasing residual pressure in brake accumulator circuit SEN04186-03
Releasing residual pressure in

brake accumulator circuit 1
k Before disconnecting any of the following

brake accumulator circuits, release resid-
ual pressure in that brake circuits.
q Piping between accumulator charge valve and

brake accumulator
q Piping between brake accumulator and brake
valve on both sides
1. Stop the engine.
2. Press the brake pedal at least 100 times to

release the pressure from the brake accumula-
tor circuit.
WA320-6 WA320PZ-6 30-120 27

SEN04186-03 Testing parking brake performance
Testing parking brake

performance 1
a Measurement condition
q Tire inflation pressure: Specified pressure
q Road: 1/5 gradient (11 20'), flat, and dry road
q Machine: Ready for operation
Measuring method
1. Start the engine and set the machine in the
straight travel position, and then drive up a
slope of 1/5 gradient with no load in the bucket.
2. Press the brake pedal to stop the machine, set

the directional lever in the N position, and stop
the engine.
3. Pull the parking brake lever fully, release the

brake pedal gradually, and check that the
machine is kept stopped.
a Measure the parking brake performance
on an uphill and a downhill.
30-120 28 WA320-6 WA320PZ-6

Testing and adjusting parking brake control cable SEN04186-03
Testing and adjusting parking Adjusting

brake control cable 1 1. Release the parking brake.
a Check that the pawl of the parking brake
Necessary tools lever is at the lowest position.
2. Loosen locknut (2) and remove clevis pin (3).
V 79A-264-0021 Push-pull scale
3. Pull parking brake lever (4) on the transfer side
k Stop the machine on a level ground, lower in the release direction. (Add the play of the
the work equipment to the ground, and set parking brake lever to the upper side, how-
chocks under the tire securely. ever.)
Testing 4. Under the above condition, tighten clevis (5) to

1. Install push-pull scale V to a position at dimen- match its hole to the hole of parking brake
sion (a) from the end of parking brake lever (1) lever (4).
(excluding the button) and pull it with a force of
294 - 392 N {30 - 40 kg}. 5. Install clevis pin (3) and tighten locknut (2).
q Dimension (a): 55 mm 3 Locknut: 5.9 9.8 Nm {0.6 1.0 kgm}
a After finishing adjustment, pull parking
2. If the parking brake lever is pulled by 8 teeth or brake lever (1) again with a force of 294 -
more, check the fixing parts of the parking 392 N {30 - 40 kg} and check that it travels
brake control cable (on both lever side and 7 clicks.
brake side) for looseness. If the fixing parts are
loosened, tighten them, and then perform the
following adjustment.
WA320-6 WA320PZ-6 30-120 29

SEN04186-03 Measuring and adjusting work equipment control lever
Measuring and adjusting work Measuring travel of work equipment control

equipment control lever 1 lever
Measure the travel at each position when operating
Necessary tools
the work equipment control lever.
Symbol Part No. Part Name a Mark the lever knob and use a scale W2 to
1 79A-264-0021 Push-pull scale measure.
a If the stroke is not within the standard value,
W Commercially
2 Scale check for play in the work equipment PPC
available valve.
k Install the frame lock bar to the frame.

a Measuring condition
q Engine coolant temperature: Operating range
of engine coolant thermometer
q Hydraulic oil temperature: 45 55C
q Engine speed: Low idle
Measuring operating effort of work equipment

control lever
Install tool W1 to the work equipment control lever
and secure it in position.
a Install tool W1 to the center of the knob.
a Operate the control lever at the same speed as
for normal operations, and measure the mini-
mum value for the effort needed to operate the
knob.
30-120 30 WA320-6 WA320PZ-6

Testing and adjusting work equipment hydraulic pressure SEN04186-03
Testing and adjusting work Adjusting

equipment hydraulic pressure 1
a Always stop the engine before adjusting the oil
Necessary tools pressure.
k When carrying out the operation with the
lift arm raised, set support [1] or lift arm
799-101-5002 Analog type hydraulic tester drop prevention stopper T in position
X
790-261-1204 Digital type hydraulic tester before starting the operation.
T 793-463-1100 Stopper
1. Remove front frame inspection cover (1).

the pressure inside the hydraulic tank, then
operate the control lever several times to
release the remaining pressure in the
hydraulic piping.
Measuring condition
Measuring
1. Install hydraulic tester X (40 MPa {400 kg/cm2})

to the oil pressure measurement nipple.
2. Remove cap nut (2) of relief valve (5).
3. Loosen locknut (3) of relief valve (5), then turn

adjustment screw (4) to adjust.
a Turn the adjustment screw to adjust the
set pressure as follows.
q TIGHTEN to INCREASE pressure
q LOOSEN to DECREASE pressure
adjustment screw: Approx. 4.2 MPa
{Approx. 42.8 kg/cm2}
a Do not carry out any adjustment if the
relief pressure cannot be measured accu-
2. Start the engine, raise the lift arm approx. 400 rately.
mm, run the engine at high idle, then operate
the control lever to tilt back the bucket, and
measure the pressure when the relief valve is
actuated.

WA320-6 WA320PZ-6 30-120 31

SEN04186-03 Testing work equipment PPC oil pressure
Testing work equipment PPC oil Checking PPC valve output pressure
pressure 1 1. Remove the inspection cover (1) of the front
frame.
k Except for measuring the oil pressure,
Necessary tools
Symbol Part No. Part Name when carrying out preparatory operations
with the lift arm raised, set support [1] or
Y lift arm drop prevention stopper T in posi-
790-261-1204 Digital type hydraulic tester tion before starting the operation.
T 793-463-1100 Stopper

the pressure inside the hydraulic tank.
Then operate the control levers several
times to release the pressure in the piping.
Measuring condition
k When leaving the operator's seat, apply the

work equipment lock lever securely.
Testing PPC valve basic pressure

2. Remove PPC output pressure measurement
1. Remove plug (4) (10 mm, P = 1.25 mm) for
plug of the circuit to be measured, then install
measuring the work equipment PPC valve
oil pressure gauge Y (6 MPa {60 kg/cm2}).
basic pressure (same as low-pressure relief
3. Start the engine, then remove support [1] or
pressure) from under the machine.
boom drop prevention stopper T.
2. Fit a nipple, then install oil pressure gauge Y (6
4. Operate the work equipment control lever at
MPa {60 kg/cm2}).
high idle and measure the oil pressure.
4. Run the engine at high idle, then operate the
work equipment control lever and measure the
oil pressure.

30-120 32 WA320-6 WA320PZ-6

Testing work equipment PPC oil pressure SEN04186-03
a A: Bucket TILT
B: Bucket DUMP
C: Lift arm RAISE
D: Lift arm LOWER

WA320-6 WA320PZ-6 30-120 33

SEN04186-03 Bleeding air from hydraulic circuit
Bleeding air from hydraulic

circuit 1
Bleeding air from work equipment PPC circuit

1. Operate each work equipment lever fully and
hold it in position to relieve the circuit for
approx. 1 minute. Carry out this operation once
for each work equipment lever stroke end.
Bleeding air from cylinders

1. Start the engine and run at idle for approx. 5
minutes.
2. Run the engine at low idle, then raise and
lower the lift arm 4 5 times in succession.
a Operate the piston rod to a point approx.
100 mm before the end of its stroke. Do
not relieve the circuit under any circum-
stances.
3. Run the engine at full throttle and repeat Step
2. After that, run the engine at low idling, and
operate the piston rod to the end of its stroke to
relieve the circuit.
4. Repeat Steps 2 and 3 to bleed the air from the
bucket and steering cylinders.
a When the cylinder has been replaced,
bleed the air before connecting the piston
rod.
30-120 34 WA320-6 WA320PZ-6

Releasing remaining pressure in hydraulic circuit SEN04186-03
Releasing remaining pressure in

hydraulic circuit 1
Releasing remaining pressure between each

hydraulic cylinder and control valve
a If the piping between the hydraulic cylinder and
the control valve is to be disconnected, release
the remaining pressure from the circuit as fol-
lows.
1. Lower the work equipment to the ground, and
stop the engine.
2. Loosen the oil filler cap slowly to release the
pressure inside the tank.
3. Operate the control lever.
a When the lever is operated 5 6 times to
release all the remaining pressure.
Releasing remaining pressure in brake accumu-

lator circuit
a If the piping between the ACC charge valve
and brake accumulator, between the ACC
charge valve and parking brake valve, and
between the accumulator and brake valve is to
be disconnected, release the remaining pres-
sure from the circuit as follows.
1. Stop the engine.
2. Depress the brake pedal at least 100 times to
release the pressure inside the brake accumu-
lator circuit.
Releasing remaining pressure in PPC accumu-

lator circuit
a If the piping between the PPC accumulator
and PPC valve is to be disconnected, release
the remaining pressure from the circuit as fol-
lows.
1. Lower the work equipment to the ground, and
stop the engine.
2. Operate the control lever 5 6 times to release
all the remaining pressure from the circuit.
WA320-6 WA320PZ-6 30-120 35

SEN04186-03 Testing and adjusting bucket positioner
Testing and adjusting bucket 2) Adjust and secure clearance (a) between
positioner 1
the sensitive surface of proximity switch
(1) and detection bar (2) to the standard
a Measuring condition range with the shim and mounting bolt of
q Engine coolant temperature: White range the proximity switch bracket.
of engine coolant thermometer a Standard clearance (a): 3 5 mm
q Hydraulic oil temperature: 45 55C a Adjust detection bar (2) with the shim
so that clearance (a) will be in the
Testing standard range through the stroke of
1. Stop the engine and check that clearance (a) the detection bar (2).
between proximity switch (1) and detection bar
(2) is in the standard range. 2. Adjusting installing position (stopping
a Standard clearance (a): 3 5 mm position).
1) Lower the bucket to the ground and set it
to a desired digging angle, then return the
lever to the HOLD position and stop the
engine.
2) Adjust with switch mounting nut (4) so that
clearance (b) of the detection bar (2) of
proximity switch (1) is within the standard
value, then secure in position.
3 Switch mounting nut:
14.7 19.6 Nm {1.5 2.0 kgm}
q The installing position may be
checked by checking the operation of
the pilot lamp of the proximity switch
with the starting switch at the ON
2. Run the engine at same as usual working position.
speed and check the operating point. (Mea- a For ON/OFF of the pilot lamp, see
sure 3 times and obtain the average.) Checking proximity switch working
pilot lamp.
Adjusting
1. Adjusting clearance.
1) Adjust and secure clearance (b) between
the tip of switch protector (3) and the sen-
sitive surface of the switch to the standard
range with switch nuts (4).
a Standard clearance (b): 0.5 1.0 mm
3 Mounting nut:
14.7 19.6 Nm {1.5 2.0 kgm}
a After adjusting, start the engine and oper-

ate the work equipment control lever to
check that the bucket positioner sets the
bucket at the desired position.
30-120 36 WA320-6 WA320PZ-6

Testing and adjusting of boom kick-out switch SEN04186-03
Testing and adjusting of boom 4. Adjust the switch so that clearance (a) between
kick-out switch 1
the sensing surface of the switch and plate (2)
is the standard value, then secure in position.
Testing 3 Switch mounting nut:
14.7 19.6 Nm {1.5 2.0 kgm}
1. With the engine stopped, check that clearance q The installing position may be checked by
(a) between detection surface of switch (1) and checking the operation of the pilot lamp of
plate (2) is the standard value. the proximity switch with the starting
a Standard clearance (a): 3 5 mm switch at the ON position.
a For ON/OFF of the pilot lamp, see Check-
ing proximity switch working pilot lamp.
a After adjusting, start the engine, operate
the work equipment control lever and
check that the boom kickout is actuated at
the desired position.
2. Start the engine, run at high idle, and check the

actuation point.
(Check three times and take the average.)
Adjusting
1. Raise the lift arm to the desired height, then

mark the lift arm to show the position where
the center of the switch is aligned with the bot-
tom of the plate.
k Always be sure to apply the work equipment
lock lever.
2. Lower the lift arm and stop the engine.
3. Align the marks and adjust the position of the

plate so that the center of switch (1) is at the
bottom of plate (2), then secure in position with
bolt (3).
WA320-6 WA320PZ-6 30-120 37

SEN04186-03 Checking proximity switch operation pilot lamp
Checking proximity switch

operation pilot lamp 1
The proximity switch has a pilot lamp to indicate its

operating condition. Use this pilot lamp when
adjusting the proximity switch.
q A: Operation pilot lamp (Red)
Positional relationship between sensitive surface

Proximity switch Operation pilot lamp Remarks
of proximity switch and sensing object
Near ON Operates when center of
Bucket positioner
Far OFF switch is near
Near ON Operates when center of
Boom kick-out
Far OFF switch is far
30-120 38 WA320-6 WA320PZ-6

Procedure for testing diodes SEN04186-03
Procedure for testing diodes 1
a Check an assembled-type diode (8 pins) and

independent diode (2 pins) in the following
manner.
a The conductive directions of the assembled-
type diode are indicated on the surface of the
diode as shown in the following figure.
2. When using analog type circuit tester

1) Switch the testing mode to resistance
range.
2) Apply the leads of the tester as explained
below and check the movement of the
pointer.
1] Put the red probe (+) of the test lead
to the anode (P) and the black probe
a The conductive directions of the single diode is () to the cathode (N) of diode.
indicated on the surface of the diode as shown 2] Apply the red (+) lead of the tester to
in the following figure. the cathode (N) side of the diode and
apply the black () lead to the anode
(P) side.
3) Determine if a specific diode is good or no
good by the way the pointer swings.
q With the connection 1] above, the
pointer is not moved. It swings, how-
ever, wh en the conn ectio n 2 ] is
employed. Normal (However, magni-
tude of the pointer's move (indicating
the resistance value) varies depend-
ing on the given tester model and the
measurement range selected).
q The pointer swings with both the con-
nections of 1] and 2]: Defective (Inter-
nal short circuit)
1. When using digital type circuit tester q The pointer does not swing with both
1) Switch the testing mode to diode range the connections of 1] and 2]: Defec-
and confirm the indicated value. tive (Internal breaking of wire)
a Voltage of the battery inside is dis-
played with conventional circuit testers.
2) Put the red probe (+) of the test lead to the
anode (P) and the black probe () to the
cathode (N) of diode, and confirm the indi-
cated value.
3) Determine acceptability of the diode from
the indicated value.
q Indicated value remains unchanged:
Conduction is absent (Failure)
q The indicated value changes: The
diode has conductivity (Normal) (See
a below.)
a A value between 460 to 600 is indi-
cated for silicon diodes.
WA320-6 WA320PZ-6 30-120 39

SEN04186-03 Preparation work for troubleshooting for electric system
Preparation work for

troubleshooting for electric
system 1
a When carrying out troubleshooting for an elec-

tric circuit related to the machine monitor,
transmission controller, work equipment con-
troller, or KOMTRAX terminal, expose the
related connectors according to the following
procedure.
a Disconnect and connect the connectors of spe-
cial lock types according to the following pro-
cedure.
1. Machine monitor 2) Remove cover (1).

1) Disconnect the following connectors from
cover (1).
q Connector L06: Hazard switch
q Connector L07:
Front working lamp switch
q Connector L08:
Rear working lamp switch
q Connector L09:
ECSS switch (If equipped)
q Connector L10:
Machine monitor mode selector
switch 1
q Connector L11:
Machine monitor mode selector
switch 2
3) Remove 3 bracket mounting bolts (3) of
a Pull the switch out of the cover and
machine monitor (2) and reverse the
disconnect each connector.
machine monitor.
a If you insert your hands from under
a Take care not to pull the wiring har-
the cover and disconnect a connector
ness forcibly.
forcibly, you many damage the con-
nector or switch. Take care.
30-120 40 WA320-6 WA320PZ-6

Preparation work for troubleshooting for electric system SEN04186-03
4) Connect diagnosis T-adapters to connec- 3. KOMTRAX terminal

tors L24 to L30 of machine monitor (2). 1) Open right door (1) and remove console
cover (2).
2. HST controller
1) Remove cover (1) from the rear of the cab. 2) Connect diagnosis T-adapter to connec-
tor L80 of KOMTRAX terminal (3).
a If the connector cannot be discon-
nected and connected easily, remove
the KOMTRAX terminal.
a Since the connector is secured with
screws, loosen those screws before
disconnecting.
a When connecting the connector again,
tighten its screws to the specified
torque.
3 Screw:
2.2 2.8 Nm {0.23 0.29 kgm}
2) Connect diagnosis T-adapters to HST

connector of HST controller (2).
WA320-6 WA320PZ-6 30-120 41

SEN04186-03 Preparation work for troubleshooting for electric system
4. Boost pressure and temperature sensor 6. Common rail pressure sensor (FUEL RAIL
(BOOST PRESS & IMT) PRESS)
a Disconnection and connection of connector a Disconnection and connection of connector
The connector of the boost pressure and The connector of the common rail pres-
temperature sensor has a special locking sure sensor has a special locking mecha-
mechanism. Disconnect it according to nism. Disconnect it according to steps (a)
steps (a) (b) and connect it according to (b) and connect it according to steps (c)
steps (c) (d) as shown below. (d) as shown below.
Disconnection: Disconnection:
(a) Unlock (b) Disconnect connector. (a) Unlock (b) Disconnect connector.
Connection: Connection:
(c) Connect connector (d) Lock. (c) Connect connector (d) Lock.
a Removal and installation of sensor a Precautions for disconnecting connector

A torque wrench is necessary for removal The direction of the lock of the connector
and installation of the boost pressure and varies with the tightened position of the
temperature sensor. See Testing adjust- sensor and the lock may be in a direction
ing, Troubleshooting tools table. in which it is difficult to reset (on the under-
side or engine side).
5. Supply pump IMV solenoid (FUEL REGU- In this case, pinch the lock in direction (a)
LATOR) with bent-nose nippers (commercially
a Disconnection and connection of connector available), and the lock is reset.
The connector of the supply pump IMV Since the lock clicks when it is reset, dis-
solenoid has a special locking mecha- connect the connector after a click is
nism. Disconnect it according to steps (a) heard.
(b) and connect it according to steps (c)
(d) as shown below.
Disconnection:
(a) Unlock (b) Disconnect connector.
Connection:
(c) Connect connector (d) Lock.
30-120 42 WA320-6 WA320PZ-6

Preparation work for troubleshooting for electric system SEN04186-03
a Precautions for connecting connector 8. Ambient pressure sensor (AMBAIR PRES-

Take care not to connect the connector SURE)
reversely. Engine Ne speed sensor (CRANK SENSOR)
Engage lock (e) on the wiring harness Engine Bkup speed sensor (CAM SENSOR)
side with triangular notch (f) on the sensor Engine oil pressure switch (OIL PRESSURE
side (Do not engage lock (e) with square SWITCH)
guide (g) on the opposite side of triangular a Disconnection and connection of connectors
notch (f)). The connectors of the ambient pressure
sensor, engine Ne speed sensor, engine
Bkup speed sensor, and engine oil pres-
sure switch have a special locking mecha-
nism. Disconnect them according to steps
(a) (c) and connect them according to
steps (d) (f) as shown below.
Disconnection: (a) Slide lever (b) Unlock
(c) Disconnect connector.
Connection: (d) Connect connector (e)
Lock (f) Slide lever.
7. Engine coolant temperature sensor (COOL-

ANT TEMP)
a Disconnection and connection of connector
The connector of the engine coolant tem-
perature sensor has a special locking
mechanism. Disconnect it according to
steps (a) (b) and connect it according to
steps (c) (d) as shown below.
Disconnection:
(a) Unlock (b) Disconnect connector.
Connection: a Removal and installation of sensor
(c) Connect connector (d) Lock. A deep socket is necessary for removal
and installation of the engine oil pressure
switch. See Testing adjusting, Trouble-
shooting tools table.
a Removal and installation of sensor

A deep socket is necessary for removal
and installation of the engine coolant tem-
perature sensor. See Testing and adjust-
ing, Troubleshooting tools table.
WA320-6 WA320PZ-6 30-120 43

SEN04186-03 Starting KOMTRAX terminal operations
Starting KOMTRAX terminal 3) When about 5 seconds elapsed after the

operations 1
starting switch was set to ACC, make sure
that the 7-segment indicator lamp
In the case where the KOMTRAX terminal has changes to hyphen on the KOMTRAX
already been installed at the plant before ship- terminal.
ment:
a Implement the following procedure in the case
where the KOMTRAX terminal has already
been installed at the plant before shipment (as
standard equipment).
1. Notification of model, part number and

serial number
Notify the KOMTRAX operations administrator
of model, part number and serial number.
2. Registration of machine
The KOMTRAX operations administrator shall
use a KOMTRAX client PC to register the
machine.
a Refer to Manual for KOMTRAX opera-
tions administrator for the procedure.
a Now the terminal is ready for use.
In the case where the KOMTRAX terminal is ret-

rofitted:
a When retrofitting the KOMTRAX terminal after
shipment (retro-fitted machine), follow the
steps below.
1. Station opening check in machine side

a Complete steps 3) to 5) within 60 sec-
onds. If 60 seconds or above elapsed,
begin with step 1) again.
4) Disconnect check connector 1, and wait
1) Turn OFF the starting switch and then,
for about 3 to 5 seconds as it is.
after making sure 5 seconds have
a Ensure that the connector is discon-
elapsed, proceed to the next step.
nected.
2) Visually check that two check connectors
5) Reconnect check connector 1, and wait
are connected.
for about 5 seconds as it is.
q Check connector 1: CHK0
a If the KOMTRAX terminal detects that
q Check connector 2: CHK1
the connector was disconnected and
connected, the dot on the 7-segment
indicator lamp blinks a few times.
30-120 44 WA320-6 WA320PZ-6

Starting KOMTRAX terminal operations SEN04186-03
6) Make sure that the 7-segment indicator a As [Normal] is indicated, proceed to

lamp is indicated normally on the the next step.
KOMTRAX terminal. a If remains displayed, execute
a If so, the 7-segment indicator lamp will steps 1) to 5) again.
indicate characters d, 0, and
repeatedly for 30 seconds after step 5)
was ended.
a Those characters, even if displayed
normally, will change to a character
other than hyphen after 30 sec-
onds or above elapsed.
The display may change to a charac-
ter other than 0 even within 30 sec-
onds.
7) Turn the starting switch to START position

for about 3 to 5 seconds, and make sure
that the engine does not start.
a If the engine starts, re-execute the
procedure above from step 1).
a Do not return the starting switch to
OFF position.
8) Turn the starting switch from ACC position
to START position again, and make sure
that the engine starts.
9) Make sure that the KOMTRAX terminal's
indicator lamps are normally turned on.
a Move on to the next step if you can
check that the display is [Normal]. (It
takes from 90 seconds to 15 minutes
before the display turns normal.)
a If [GPS position data detection trou-
ble] is indicated, check if there is any
abnormality on the GPS antenna or
cable. If there is any abnormality,
repair it and start from procedure 1)
again.
a If [Reception trouble] is indicated,
check if there is any abnormality on
the appearance of the communication
antenna or cable. If there is any
abnormality, repair it then repeat from
procedure 1) again.
a If [GPS position data detection trouble
and reception trouble] is indicated,
check if there is any abnormality on
the GPS antenna/cable or communi-
cation antenna/cable. If there is any
abnormality, repair it and start from
procedure 1) again.
WA320-6 WA320PZ-6 30-120 45

SEN04186-03 Starting KOMTRAX terminal operations
a If [Network trouble] is indicated, 10) Turn the starting switch OFF.

check the display of [LED-C4] refer- 11) Make sure that the 7-segment indicator
ring to Lamp display of KOMTRAX lamp is displayed normally after 5 seconds
terminal. If the CAN is not recog- elapsed.
nized, check the CAN harness of the a When [Normal] appears, station
KOMTRAX terminal, and then if there opening check is completed.
is any abnormality, repair it and start a If [Abnormal] appears, station open-
from procedure 1) again. ing check does not end normally, so
[A]: Normal you should perform the procedure
[B]: GPS position data detection trou- above from step 1) again.
ble a If station opening check ends nor-
[C]: Reception trouble mally, it should not be rechecked.
[D]: GPS position data detection trou-
ble and reception trouble
[E]: Network trouble
12) When station opening check ended nor-

m a l l y, a c o m m u n i c a t i o n w i t h t h e
KOMTRAX server starts automatically,
and settings are stored in KOMTRAX.
(This requires about 25 minutes to 4
hours.)
a During this time, you may turn the
starting s witc h off and start the
engine.
a During the communication and check
above, you should park the machine
outside to enable a frequent commu-
nication with the ORBCOMM satellite.
The station opening check may not
be completed in doors that cause
radio waves from the satellite to be
intercepted.
30-120 46 WA320-6 WA320PZ-6

Starting KOMTRAX terminal operations SEN04186-03
2. Application for the start of use

a Application for the start of use should be
made only after the sign-up test is fin-
ished.
1) Notify the KOMTRAX operations adminis-
trator of the following information about
the machine that completed the station
opening check in the machine side.
1] Information (model, part number, and
serial number) about the machine
that completed the station opening
check in the machine side
2] Part number and serial number of
KOMTRAX terminal
3] Value of service meter when the
KOMTRAX terminal was installed (in
0.1 hours)
2) The KOMTRAX operations administrator

shall use a KOMTRAX client PC to regis-
ter the machine.
a Refer to Manual for KOMTRAX oper-
ations administrator for the proce-
dure.
a Now the terminal is ready for use.
WA320-6 WA320PZ-6 30-120 47

SEN04186-03 Indicator lamps of KOMTRAX terminal
Indicator lamps of KOMTRAX terminal 1
LED lamps for CPU 7-segment and dot displays for CPU
1. LED-C1 (State of R or ACC signal) 7. 7 segments (Number of unsent mails)
2. LED-C2 (Starting output state) 8. Dot (GPS positioning state)
3. LED-C3 (State of S-NET or C signal)
4. LED-C4 (CAN state)
5. LED-C5 (Download write state)
30-120 48 WA320-6 WA320PZ-6

Indicator lamps of KOMTRAX terminal SEN04186-03
In the KOMTRAX system, various information and processing details are displayed on the LED on the upper
surface of the KOMTRAX terminal. Therefore, if a detect is suspected in the system, perform the following
checks.
q Check of antennas
q Check of terminal LED displays
Before using the KOMTRAX system, make sure that the application for starting its use is completed as well
as the station opening check in the machine side.
Check of antennas
a Before checking the LED displays, check that there is no abnormality around the communication
antenna and GPS antenna.
q The communication antenna should not be off or damaged.
q The communication antenna cable should not be broken and normally be connected to the KOMTRAX
terminal.
q The GPS antenna should not be off or damaged.
q The GPS antenna cable should not be broken and normally be connected to the KOMTRAX terminal.
Check of terminal LED displays

1. Meaning of CPU LED displays
a The LED displays should be checked with the starting switch ON, starting switch START, or with the
engine started.
Display
No. LED Name/function Description
(*1)
ON Starting switch ACC signal: ON, Alternator R signal: ON
States of starting switch Fast blink Starting switch ACC signal: OFF, Alternator R signal: ON
1 LED-C1 ACC signal and alternator R
signal Slow blink Starting switch ACC signal: ON, Alternator R signal: OFF
OFF Starting switch ACC signal: OFF, Alternator R signal: OFF
ON Engine control signal: ON
2 LED-C2 State of engine control signal
OFF Engine control signal: OFF
ON S-NET: Connected, Starting switch C signal: OFF
States of S-NET connection Fast blink Starting switch C signal: ON
3 LED-C3
and starting switch C signal Slow blink (Not used)
OFF S-NET: Not connected, Starting switch C signal: OFF
ON CAN: Connected (without fuel sensor)
Fast blink CAN: Connected (with fuel sensor)
4 LED-C4 State of CAN connection
Slow blink CAN: Not connected (with fuel sensor)
OFF CAN: Not connected (without fuel sensor)
5 LED-C5 1-LED ON Download write mode (system administrator only function)

Download write state
2-LED
6 LED-C6 Normal operation mode
OFF
*1: Blink types and blink times

Fast blink: Blinks in about 1-second cycle
Slow blink: Blinks in about 4-second cycle
WA320-6 WA320PZ-6 30-120 49

SEN04186-03 Indicator lamps of KOMTRAX terminal
2. Contents of 7-segment and dot displays for CPU

a The LED display should be checked with the starting switch turned ON.
Display
No. LED Name/function Description
(*2)
The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by 9.) Light-on indicates that the
Number of unsent displayed
machine is in process of capturing the satellite.
7 7 segments mails, satellite
capture state The number indicates the number of unsent mails. (10 or more
0 to 9
unsent mails are indicated by 9.) Fast blink indicates that the
fast blink
satellite is not captured.
GPS positioning was completed. (The position can be con-
ON
GPS positioning firmed. *3)
8 Dot
status GPS positioning was not completed. (The position cannot be
OFF
confirmed. *3)
*2: Blink types and blink times

Fast blink: Blinks in about 0.5-second cycle
Slow blink: Blinks in about 2.0-second cycle
*3: Supplementary explanation of GPS positioning status
One or more minute may be taken until GPS positioning is completed after the starting switch was
turned ON even in an outdoor service area.
GPS positioning will fail in a weak signal or non-service area.
30-120 50 WA320-6 WA320PZ-6

Indicator lamps of KOMTRAX terminal SEN04186-03
WA320-6 WA320PZ-6 30-120 51

SEN04186-03

2011 KOMATSU
All Rights Reserved
30-120 52
SEN04187-01
WA320-6
WA320PZ-6
WA320-6 70001 and up

30 Testing and adjusting 30

Adjusting machine monitor.............................................................................................................................. 2
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor.............................. 3
Special functions of machine monitor (EMMS) ............................................................................................... 5
Pm clinic inspection chart ............................................................................................................................. 58
WA320, 320PZ-6 30-130 1

SEN04187-01 Adjusting machine monitor
Adjusting machine monitor 1
Layout of rotary switches (SW1, SW2, and SW3) and DIP switches (SW5 and SW6)
q Do not change the setting of the rotary switches (SW1, SW2, and SW3) and DIP switches (SW5 and
SW6) on the back side of the machine monitor.
q The switches shown in the figure are set as when the monitor is delivered.
30-130 2 WA320, 320PZ-6

Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor SEN04187-01
Adjusting replaced, reassembled or added sensor, controller, etc. with

machine monitor 1
1. Items to be set when sensor or controller is replaced, reassembled or added

a If any of the following components and parts is replaced or reassembled, initialize the sensors,
solenoids, etc. with the machine monitor.
a Adjust the items in alphabetical order (A ) with the machine monitor.
Replaced, reassembled, or added component or option Adjustment item
Machine monitor A, B, C
HST controller A, B
Change of tire size B
Addition or removal of option B
Adjustment item Contents of adjustment Description No.

A Selection of machine model 12 (*1)
B Selection of option 10 (*1)
C Inputting of machine serial No. 11 (*1)
*1: Description No. of Service mode in Special functions of machine monitor (EMMS)
WA320, 320PZ-6 30-130 3

SEN04187-01 Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
2. Adjustment for user's needs

If the user makes the following indications or requests, change or adjust the items shown below with the
machine monitor.
Contents of indication/request Adjustment item
Change indication unit of speedometer (*2) D
Turn ECO lamp OFF E
Change interval of fan automatic reverse operation (Automatic reverse fan specification) F
Change continuance of fan automatic reverse operation (Automatic reverse fan specification) G
Travel speed is indicated too quickly/slowly H
Turn engine speed/travel speed on character display OFF J
ECSS operates at high or low travel speed K
Change display of major indication in engine speed (*3) L
Adjustment item Contents of change/adjustment Description No. (*1)

D Setting of option/Selection of speed unit (*2) 10
E Setting of option/Selection of indication of ECO lamp 10
Adjustment of sensor/Adjustment of interval of fan automatic
F 71
reverse operation
Adjustment of sensor/Adjustment of continuance of fan automatic
G 72
reverse operation
H Setting of option/Change of tire size 10
Setting of option/Change of indication of engine speed or travel
J 10
speed on normal screen of character display
M Adjustment of ECSS operation travel speed 75
No. 10 of
L Travel speed/engine speed display/non-display select
"Operator mode"
*1: Description No. of Service mode in Special functions of machine monitor (EMMS)
*2: Change of the indication unit of the speedometer of the specification for the SI unit countries cannot be
set.
*3: When selecting NO ADD in optional select, cannot change travel speed/engine speed.
30-130 4 WA320, 320PZ-6

Special functions of machine monitor (EMMS) SEN04187-01
Special functions of machine monitor (EMMS) 1
a EMMS: Equipment Management Monitoring System
1. Machine monitor mode change switch 1

2. Machine monitor mode change switch 2
3. Character display
WA320, 320PZ-6 30-130 5

SEN04187-01 Special functions of machine monitor (EMMS)
Normal functions and special functions of machine monitor

The machine monitor is equipped with the normal functions and special functions. Various items of data are
displayed on the character display in the middle of the machine monitor.
Depending on the internal setting of the machine monitor, the display items are divided into automatic dis-
play items and items displayed when the machine monitor switches are operated.
1) Normal functions: Operator mode
Functions for which the content is normally displayed or which can be displayed and operated by the
operator operating the switches.
a See the Operation and maintenance manual for details of the operator mode.
2) Special functions: Service mode
Functions which the serviceman can display and operate with the special switches to carry out inspec-
tion, maintenance, and troubleshooting.
No. No.
Operator mode Service mode
(*1) (*1)
1 Service meter display function 2 Electrical system fault history display function
2 Traction level selection function 3 Mechanical system fault history display function
3 HST function selection function 4 Real-time monitoring function
4 Odometer display function 5 Engine cylinder cut-out function
5 Maintenance monitoring function 6 No injection cranking function
6 Telephone number input function 7 Adjustment function

7 Language selection function 8 Maintenance monitoring function
8 Monitor brightness adjustment function 9 Operating information display function
Travel speed/engine speed display selecting
9 10 Optional device selecting function
function (*2)
Function of turning ON/OFF travel speed/
10 11 Machine serial number input function
engine speed display on character display (*3)
11 Action code display function 12 Model selection function
12 Failure code display function 13 Initialize function
14: Item that refers to SERVICE NEWS (*4)
*1: No. shows an item number in this document.

*2: q Not displayed if SI unit specification is set when delivered.
q Not displayed if RPM OPT is turned NO ADD by selecting an optional device in the service mode.
*3: Not displayed if Travel speed/Engine speed on character display is turned NO ADD by selecting an optional device
in the service mode.
*4: Not include Service mode
30-130 6 WA320, 320PZ-6

Functions and flow of service mode

Note: Some items may not be used, depending on the setting and specification, although they are displayed
on the monitor. (For details, see the text.)
WA320, 320PZ-6 30-130 7

30-130 8 WA320, 320PZ-6

WA320, 320PZ-6 30-130 9

Operator mode 3. HST function selection function

a The operator mode is outlined below. While the speed range selector switch is in the
a For details of the operator mode, see Struc- 3rd or 4th gear speed position, the reverse
ture, function and maintenance standard or speed range can be set to 2 levels.
Operation and Maintenance Manual. a For details, see Operation and Mainte-
nance Manual, Operation, Other func-
1. Service meter display function tions of machine monitor.
If the starting switch is turned ON, the service
meter is displayed on the above line and the
engine speed is displayed on the lower line.
a If the engine speed is displayed at the
center of the monitor, the travel speed is
displayed.
4. Odometer display function

The odometer is displayed.
a For details, see Operation and Mainte-
tions of machine monitor.
2. Traction level selection function

Press [U] switch on the ordinary service meter
display screen, and the screen to set the trac-
tion level selection function is displayed.
a If the traction control is turned ON with the
traction control switch, the traction can be
set to 3 levels.
a For details, see Operation and Mainte-
tions of machine monitor.
a For items 3 and after, display a desired

screen with [<] or [>] switch on the Trac-
tion level selection function screen.
a Each time [<] or [>] switch is pressed, the
screen changes in order. Repeat either
switch until a desired screen is displayed.
30-130 10 WA320, 320PZ-6

5. Maintenance monitoring function 7. Language selection function

1) Filter, oil replacement time display (auto- Switch operation allows selecting a display lan-
matic display) guage of the machine monitor.
As the filter or oil replacement time draws a Functions of the service mode are con-
close, the machine monitor automatically stantly displayed in English since they are
displays its information to alert operator's exempted from the display selection func-
attention. tion.
2) Resetting replacement time (selection a A desired language is selectable from
menu) English, Japanese, German, French, Ital-
As maintenance operation for a filter or oil ian, Spanish and Swedish.
is completed, the machine monitor allows a For details, see the Other functions of
resetting the time interval through the machine monitor of the Operation section
switch operation. in the Operation and maintenance man-
a For details, see the Other functions ual.
of machine monitor of the Opera-
tion section in the Operation and
maintenance manual.
6. Telephone number input function

Telephone numbers are entered through the
switch operation. And modification or cancella-
tion of the phone numbers in the machine
monitor is also available through the switch
operation.
a When action code [E03] is displayed, a
phone number is displayed along with
[CALL].
a For details, see the Other functions of
machine monitor of the Operation section
in the Operation and maintenance man-
ual.
WA320, 320PZ-6 30-130 11

8. Monitor brightness adjustment function 9. Travel speed/engine speed display select-

Brightness of the machine monitor is adjustable ing function
in seven levels through the switch operation. A unit to be used for the machine monitor
a Adjustment of brightness is available in speed display is selectable from km/h and
two approaches adjustment of the moni- MPH. It is also possible to turn on or off the dis-
tor alone and separate adjustment of the play of the travel speed and engine speed.
monitor and liquid crystal. a For details, see the Other functions of
a For details, see the Other functions of machine monitor of the Operation section
machine monitor of the Operation section in the Operation and maintenance man-
in the Operation and maintenance manual. ual.
10. Travel speed/engine speed display/non-dis-

play selecting function
A unit for the machine monitor speed display is
selectable from km/h and MPH. It is also possi-
ble to turn on or off display of the travel speed
and engine speed.
a For details, see the Other functions of
machine monitor of the Operation section
in the Operation and maintenance man-
ual.
30-130 12 WA320, 320PZ-6

11. Action code display function

If a trouble occurs, the machine monitor dis-
plays an action code corresponding to the seri-
ousness of the trouble to alert the operator for
appropriate actions.
a The figure below shows an example of the
screen on which action code [E03] and
[CALL + Telephone number] are alter-
nately displayed.
a When action code [E01] or [E02] is dis-
played, [CALL + Telephone number] is not
displayed.
a Action codes and actions alerted to operator

CALL + Tele-
Action code Actions recommended to operator
phone number
Do necessary testing and/or servicing as the current work is over or at
E01 Not displayed
shift of the operator.
When an overrun-related item is displayed:
Slow down the engine or machine speed.
E02 Not displayed
When an overheat-related item is displayed:
Stop the machine and run the engine at mid speed with no load.
E03 Displayed Stop the engine and machine immediately and contact a serviceman.
WA320, 320PZ-6 30-130 13

12. Failure code display function a The service code display function displays
Pressing [>] switch once while an action is dis- the following information.
played on the machine monitor displays the A: Failure code
failure code corresponding to the failure cur- B: Controller code
rently warned. MON: Machine monitor
a The failure codes detected in the past are HST: HST controller
divided into failures of the electrical sys- ENG: Engine controller
tem and the mechanical system and are C: The system where failure occurred
recorded as fault history. (For details, see
Service mode.)
a When two or more failures are involved,
pressing [>] switch displays further codes.
a If [>] switch is pressed again after it was
pressed to display every involved failure
code, the service meter display screen will
be restored.
Pressing [>] switch one more time dis-
plays the failure codes from the first.
If [>] switch is not touched for 30 seconds,
the action code display screen is automat-
ically displayed.
a For details of a displayed failure code, see

Failure code list.
a If any switch operation is not done for 30
seconds or more on the failure code dis-
play screen, the action code display
screen is automatically turned on.
30-130 14 WA320, 320PZ-6

Service mode (*1): When the cursor is located at the left-

1. Procedure for switching to Service mode most position, pressing the switch
and screen display restores the normal screen (Operator
Reference: The service meter is displayed in mode).
English, regardless of language When the cursor is at a location other
selection in the operator mode. than the leftmost position, pressing
When using Service mode, carry out the fol- the switch returns the cursor to the
lowing special operation to switch the screen leftmost position.
display. If any switch operation is not done for
1-1. Checking screen display 60 seconds or more from ID input
Make sure that the machine monitor is set to screen, the normal screen is automat-
the operator mode and any of Service meter, ically turned on.
Action code or Failure code is displayed on
the screen.
1-2. Displaying ID input initial screen
Hold down [t] switch and [<] switch simulta-
neously for 5 seconds minimum to open ID
input initial screen.
a Holding down the two switches for 5 sec-
onds or more makes the entire screen
blank. As this state is recognized, release
the buttons.
1-4. Displaying menu initial screen

a After settling 4-digit ID, turn on the menu
initial screen of Service mode.
a Once entered and settled, an ID remains
effective until the starting switch is turned
off.
1-3. Inputting and confirming ID

Operate the buttons to input the ID.
q ID: 6491
1) Cursor (C) is positioned at the highest-
order digit. Pressing [<] and [>] switches
changes the value of this digit in the range
of 0 9.
2) Press [U] switch when the intended value
appeared to specify it.
a The cursor moves to the 2nd digit.
3) Set the value in the same order and then 1-5. Selecting service mode menu
press [U] switch. a Pressing [<] and [>] switches from the
a When you have entered a wrong value to menu screen displays Service mode
a position except the highest-order digit, menus endlessly in the following order.
move to the highest-order digit using [t] a The menus are displayed in the field indi-
switch to repeat the procedure from the cated with [*] mark.
first. In this case, values that had been [1] ELECTRIC FAULT: Electrical system
entered remain as they are until modified. fault history display function
When the cursor is at the highest-order [2] MACHINE FAULT: Mechanical sys-
digit, it can move to the higher layer using tem fault history display function
[t] switch. (*1). [3] REAL-TIME MONITOR: Real-time
monitoring function
WA320, 320PZ-6 30-130 15

[4] CYLINDER CUT-OUT: Engine 2. Electrical system fault history display func-
reduced-cylinder function tion (ELECTRIC FAULT)
[5] NO INJECTION: No injection crank- The machine monitor records the past failures
ing function in the electric system as the failure codes. The
[6] TUNING: Adjustment function failure codes are displayed from the following
[7] MAINTENANCE MONITOR: Mainte- operations.
nance monitoring function 2-1. Selecting the menu
[8] OPERATION INFO: Operating infor- Select the ELECTRIC FAULT from the menu
mation display function screen of Service mode.
[9] OPTIONAL SELECT: Optional device a [**] field displays total number of the fault
selecting function history currently recorded (up to 20
[10] MACHINE No. SET: Machine serial cases).
number input function
[11] MACHINE: Model selection function
[12] INITIALIZE: Initialize function (Func-
tion specialized for plant)
a The menu is indicated in the parts of [*].
2-2. Displaying fault history

Press [U] button while the menu is selected to
display the recorded fault history.
1-6. Completion of mode and function

Either of the following procedures ends a
mode or function independent of the function
being selected and the layer in which it is used.
1) When the operation is to be continued
using another mode or function: Press [t]
switch to return to the mode screen or
menu screen to be used next.
a Note, however, that [t] switch functions
as an execution key on [YES/NO] screen.
a When the normal screen (Operator mode)
was inadvertently turned on, repeat above
steps from 1) (input of the ID is not neces- 2-3. Displayed fault history
sary). The electric system fault history display func-
2) When ending an operation completely: tion displays the following information.
Turn the starting switch off from the cur- A: Record number
rent state. B: Failure code (Location code in four digits +
Problem code in two digits)
C: Number of occurrences (number of occur-
rences of same code in past)
D: Elapsed time 1 (Elapsed time on service
meter from the first occurrence)
E: Elapsed time 2 (Elapsed time on service
meter from the last occurrence)
a The code of a failure currently occurring is
indicated in flashing.
30-130 16 WA320, 320PZ-6

a For details of a displayed failure code, see 2-6. Deleting all fault history
Failure code list of the failure code dis- 1) Press [<] or [>] switch while the fault his-
play function. tory is on the screen to display the ALL
a Note that part of the information displayed CLEAR menu screen.
from the electrical system fault history dis-
play function and the failure code display
function is not identical.
a When the requested fault history is not
recorded, [] is indicated in the display
space.
2) Press [U] switch to display the ALL

CLEAR screen.
3) Select YES or NO using [<] or [>]
switch.
a The selected cursor will start flashing. If
YE S is s elec ted a nd [t] s witc h is
2-4. Switching fault history display pressed, the information will be deleted. If
Pressing [<] or [>] switch while a set of fault NO is selected and [t] switch is
history is on the screen displays another set of pressed, deletion is cancelled and the
recorded fault history. Maintenance interval change item
2-5. Deleting individual fault history screen is restored.
1) Press [U] switch while the target fault his- a By default, the cursor is set to NO (cancel)
tory of deletion is on the screen to turn on to prevent resetting error.
CLEAR screen. a Information of the currently occurring fail-
2) Select YES or NO using [<] or [>] switch. ure is not deletable.
Y ES i s s ele cted and [t] s witc h i s
pressed, the information will be deleted. If
NO is selected and [t] switch is
pressed, deletion is cancelled and the
Maintenance interv al c hange item
screen is restored.
a By default, the cursor is set to NO (cancel)
to prevent resetting error.
a Information of the currently occurring fail-
ure is not deletable.
WA320, 320PZ-6 30-130 17

3. Mechanical system fault history display 3-3. Displayed fault history

function (MACHINE FAULT) The mechanical system fault history display
The machine monitor records the past failures function displays the following information.
in the mechanical system as the failure codes.
The failure codes are displayed from the fol- A: Record number
lowing operations. B: Failure code (Location code in four digits +
3-1. Selecting the menu Problem code in two digits)
a Select MACHINE FAULT from the menu C: Number of occurrences (number of occur-
screen of Service mode. rences of same code in past)
a [**] field displays total number of the fault D: Occurrence time 1 (Time on service meter
history currently recorded. at the first occurrence)
E: Occurrence time 2 (Time on service meter
at the last occurrence)
a The code of a failure currently occurring is
indicated in flashing.
a For details of a displayed failure code, see
Failure code list of next page.
a Note that part of the information displayed
from the mechanical system fault history
display function and the failure code dis-
play function is not identical.
a When the requested fault history is not
recorded, [] is indicated in the display
space.
3-2. Displaying fault history

Press [U] switch while the menu is selected to
display the recorded fault history.
3-4. Switching fault history display

Pressing [<] or [>] switch while a set of fault
history is on the screen displays another set of
recorded fault history.
3-5. Deleting fault history (Not available)
The fault history of the mechanical system is
not deletable.
30-130 18 WA320, 320PZ-6

Failure codes table

Failure Action Category of
Troubled part/item Trouble Controller
code code record
Mechanical
2G40ZG Brake Oil pressure reduction MON E03
system
Mechanical
6091NX HST filter Clogging MON E01
system
Mechanical
989FN1 Travel speed Overrun alarm MON E02
system
Mechanical
AA1ANX Air cleaner Clogging MON E01
system
Electrical
AB00L6 Alternator R system Hot short MON E01
system
Ground fault/Disconnection/Low Electrical
AB00MA Alternator R system MON E03
charge level system
Mechanical
B@BAZG Engine Oil pressure reduction ENG E03
system
Mechanical
B@BAZK Engine oil Low oil level MON E01
system
Mechanical
B@BCNS Engine Overheat ENG E02
system
Mechanical
B@BCZK Engine Low coolant level MON E01
system
Mechanical
B@C6NS Front brake High oil temperature MON E02
system
Mechanical
B@CRNS HST High oil temperature MON E02
system
Electrical
CA111 Engine controller Internal abnormality ENG E03
system
Electrical
CA115 Engine NE, Bkup speed sensor Abnormality ENG E03
system
Electrical
CA122 Charge pressure sensor Abnormally high level ENG E03
system
Electrical
CA123 Charge pressure sensor Abnormally low level ENG E03
system
Electrical
CA131 Throttle sensor Abnormally high level ENG E03
system
Electrical
CA132 Throttle sensor Abnormally low level ENG E03
system
Electrical
CA144 Coolant temperature sensor Abnormally high level ENG E01
system
Electrical
CA145 Coolant temperature sensor Abnormally low level ENG E01
system
Electrical
CA153 Charge temperature sensor Abnormally high level ENG E01
system
Electrical
CA154 Charge temperature sensor Abnormally low level ENG E01
system
Electrical
CA155 Charge temperature Abnormally high speed derate ENG E03
system
Electrical
CA187 Sensor power supply 2 Abnormally low level ENG E03
system
Electrical
CA221 Ambient pressure sensor Abnormally high level ENG E01
system
WA320, 320PZ-6 30-130 19


code code record
Electrical
CA222 Ambient pressure sensor Abnormally low level ENG E01
system
Electrical
CA227 Sensor power supply 2 Abnormally high level ENG E03
system
Mechanical
CA234 Engine Overspeed ENG E02
system
Electrical
CA238 Ne speed sensor power supply Abnormality ENG E03
system
Electrical
CA271 IMV (IMA) Short circuit ENG E03
system
Electrical
CA272 IMV (IMA) Disconnection ENG E03
system
Electrical
CA322 Injector #1 system Disconnection/Short circuit ENG E03
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
system
Electrical
CA342 Engine controller Data mismatching ENG E03
system
Electrical
CA351 Injector drive circuit Abnormality ENG E03
system
Electrical
system
Electrical
system
Electrical
CA428 Water sensor Abnormally high level ENG E01
system
Electrical
CA429 Water sensor Abnormally low level ENG E01
system
Electrical
CA431 Idle validation switch Abnormality ENG E01
system
Electrical
CA432 Idle validation switch Abnormal remedy ENG E03
system
Electrical
CA435 Engine oil pressure switch Abnormality ENG E01
system
Electrical
CA441 Power supply voltage Abnormally low level ENG E03
system
Electrical
CA442 Power supply voltage Abnormally high level ENG E03
system
Electrical
CA449 Common rail pressure Abnormally high pressure 2 ENG E03
system
Electrical
CA451 Common rail pressure sensor Abnormally high level ENG E03
system
30-130 20 WA320, 320PZ-6


code code record
Electrical
CA452 Common rail pressure sensor Abnormally low level ENG E03
system
Electrical
CA488 Charge temperature Abnormally high torque derate ENG E03
system
Electrical
CA553 Common rail pressure Abnormally high pressure 1 ENG E03
system
Electrical
CA559 Supply pump Low rail pressure 1 ENG E03
system
Electrical
CA689 Engine Ne speed sensor Abnormality ENG E03
system
Electrical
CA731 Engine Bkup speed sensor Abnormal phase ENG E03
system
Electrical
CA757 Engine controller Loss of all data ENG E03
system
Electrical
CA778 Engine Bkup speed sensor Abnormality ENG E03
system
Electrical
CA1633 KOMNET Abnormality ENG E03
system
Electrical
CA2185 Throttle sensor power supply Abnormally high level ENG E03
system
Electrical
CA2186 Throttle sensor power supply Abnormally low level ENG E03
system
Electrical
system
Electrical
CA2311 IMV (IMA) solenoid Abnormality ENG E03
system
Electrical
CA2555 Intake air heater relay Disconnection ENG E01
system
Electrical
CA2556 Intake air heater relay Short circuit ENG E01
system
Electrical
D160KY Backup lamp/buzzer relay Hot short MON E01
system
Electrical
D192KY ECSS solenoid relay Hot short MON E01
system
Electrical
D1B0KA HST safety relay Disconnection HST E03
system
Electrical
D1B0KB HST safety relay Ground fault HST E01
system
Electrical
D1B0KY HST safety relay Hot short HST E03
system
Electrical
D5ZHL6 IGN C system Ground fault/Disconnection MON E01
system
Electrical
DAF3KK UNSW power supply Ground fault/Disconnection MON E01
system
Electrical
DAFRKR Monitor panel CAN-NET signal Disconnection HST E03
system
Electrical
DAJ0KK HST controller power supply Low voltage HST E03
system
HST controller memory Electrical
DAJ0KT Abnormality HST E01
(EEPROM) system
WA320, 320PZ-6 30-130 21


code code record
Electrical
DAJ1L4 HST controller main power line Disconnection/Ground fault HST E01
system
Electrical
DAJ1L6 HST controller main power line Hot short HST E01
system
Electrical
DAJ2KK Controller solenoid power supply Low voltage HST E03
system
HST controller load power supply Electrical
DAJ2L3 Hot short HST E01
holding line system
HST controller load power supply Electrical
DAJ2L4 Disconnection/Ground fault HST E01
holding line system
Electrical
DAJ5KX Sensor 5V power supply Out of input range HST E03
system
(DAJ9KQ) HST controller Disagreement in model selection MON E03
Electrical
DAJRKR HST controller CAN-NET Disconnection in signal line MON E03
system
(DAJRMA) HST controller Disagreement in option selection MON E03
Electrical
DB2RKR Engine controller CAN-NET Disconnection in signal line HST E03
system
Electrical
DD1NL4 Fan auto reverse switch signal Abnormality HST E01
system
Electrical
DD1NLD Fan reverse switch signal Abnormality HST E01
system
Electrical
DDB6KA Parking brake reminder signal Disconnection/Hot short HST E01
system
Electrical
DDB6KB Parking brake indicator signal Ground fault HST E01
system
Parking brake indicator signal or Electrical
DDB6KZ Trouble MON E03
parking brake reminder signal system
Electrical
DDB6L0 Parking brake reminder signal Ground fault HST E01
system
Electrical
DDB6L4 Parking brake indicator signal Disconnection/Hot short HST E03
system
Electrical
DDD7KX Travel speed control dial Disconnection/Ground fault HST E01
system
Electrical
DDD7KY Travel speed control dial Hot short HST E01
system
Emergency steering operation Electrical
DDE5MA Disconnection MON E01
switch system
Electrical
DDK6KA FNR lever Disconnection/Ground fault HST E03
system
Electrical
DDK6KY FNR lever Hot short HST E03
system
Low oil pressure (Operation of Mechanical
DDS5L6 Steering MON E03
emergency steering) system
Travel speed range selector Electrical
DF10KA Disconnection/Ground fault HST E01
switch system
Travel speed range selector Electrical
DF10KB Hot short HST E01
switch system
Electrical
DGH1KX HST oil temperature sensor Ground fault MON E01
system
30-130 22 WA320, 320PZ-6


code code record
Electrical
DGR2KB Brake oil temperature sensor Ground fault MON E01
system
Electrical
DGR2KZ Brake oil temperature sensor Disconnection/Hot short MON E01
system
Electrical
DHH1KX HST oil pressure sensor Disconnection/Ground fault HST E03
system
Electrical
DHH1KY HST oil pressure sensor Hot short HST E03
system
Electrical
DHTCL6 HST filter clogging sensor Functional defect MON E01
system
Electrical
DJF1KA Fuel level sensor Disconnection/Hot short MON E01
system
Electrical
DLT3KX Travel speed sensor B Abnormality HST E03
system
Electrical
DLT4KX Travel speed sensor A Abnormality HST E03
system
Electrical
DLT4LC Travel speed sensor A & B Abnormality HST E03
system
Electrical
DV00KY Alarm buzzer Hot short MON E01
system
Electrical
DW26KA Motor 2 solenoid Disconnection/Ground fault HST E01
system
Electrical
DW26KY Motor 2 solenoid Hot short HST E01
system
Electrical
DW7BKY Fan reverse solenoid circuit Hot short HST E01
system
Electrical
DW7BKZ Fan reverse solenoid circuit Disconnection/Ground fault HST E01
system
Electrical
DX16KA Fan EPC solenoid Disconnection HST E01
system
Electrical
DX16KB Fan EPC solenoid Ground fault HST E01
system
Electrical
DX16KY Fan EPC solenoid Hot short HST E01
system
Electrical
DX19KA Motor 1 solenoid Disconnection HST E03
system
Electrical
DX19KB Motor 1 solenoid Ground fault HST E03
system
Electrical
DX19KY Motor 1 solenoid Hot short HST E03
system
Electrical
DX20KA Clutch EPC solenoid Disconnection HST E03
system
Electrical
DX20KB Clutch EPC solenoid Ground fault HST E03
system
Electrical
DX20KY Clutch EPC solenoid Hot short HST E03
system
Electrical
DXH7KB Reverse solenoid Ground fault HST E03
system
Electrical
DXH7KZ Reverse solenoid Disconnection/Hot short HST E03
system
WA320, 320PZ-6 30-130 23


code code record
Electrical
DXH8KB Forward solenoid Ground fault HST E03
system
Electrical
DXH8KZ Forward solenoid Disconnection/Hot short HST E03
system
Mechanical
J141N1 Steering pump Overrun alarm HST E02
system
Mechanical
M100N1 HST pump Overrun alarm HST E02
system
Mechanical
M400N1 Motor 1 Overrun alarm HST E02
system
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable controller:
Applicable controller indicates in which controller system the failure has occurred.
MON : machine monitor system
ENG : Engine controller system
HST : HST controller system
a Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
a Note: Optional equipments are also included in the table.
30-130 24 WA320, 320PZ-6

4. Real-time monitoring function 4-3. Selecting sub menu

(REAL-TIME MONITOR) a Press [<] or [>] switch from the sub menu
The machine monitor checks state of the screen to display the sub menus endlessly
machine on real-time basis referencing signals in the following order.
of the sensors being installed in various parts a The sub menus are displayed in the field
of the machine. indicated with [*] mark.
The real-time monitoring functions displays fol- [1] MONITOR PANEL: Machine monitor
lowing two types of information. system
q 1 item independent display [2] HST: HST controller system
(for each controller) [3] ENGINE: Engine controller system
q 2 items simultaneous display [4] 2 ITEMS: 2 items display
(code input)
4-1. Selecting the menu
Select REAL-TIME MONITORING from the
menu screen of Service mode.
4-4. Setting the 1 item individual monitoring

1) Select the target controller system of mon-
itoring from the sub menu screen.
4-2. Displaying sub menu

Press [U] switch while the menu is selected to
display the sub menu initial screen.
2) Press [U] switch while the sub menu is

selected to display the MONITOR PANEL
screen.
WA320, 320PZ-6 30-130 25

3) Press [<] or [>] switch to select a monitor- 4-5. Setting 2 items simultaneous monitoring
ing item. 1) Select 2 ITEMS from the sub menu
a The monitoring items are scrolled accord- screen.
ing to the internally set order. 2) Press [U] switch while the sub menu is
a Holding down [U] switch turns on high- selected to display the monitoring code
speed scrolling. input screen.
a Holding and cancelling the monitoring
data: Pressing [U] switch while the moni-
toring is in progress holds the monitoring
data and [U] mark starts flashing.Press-
ing [U] switch again restores the active
state.
1] This cursor (C) is located at the high-

est-order digit. Pressing [<] or [>]
switch changes the value of this digit
in the range of 0 9.
2] Press [U] switch when the intended
value appeared to specify it as the set
4) Display data for 1 item individual monitor- value.
ing a The cursor moves to the 2nd position.
The 1 item individual monitoring screen 3] Set the value in the same order and
displays the following information. then press [U] switch.
A: Item display a When you have entered a wrong
B: Monitoring codes (5 digits) value to a position except the highest-
1: Monitoring data order digit, the cursor can move to the
(including the unit used) highest-order digit using [t] switch
a See the Real-time monitoring code and repeat the procedure from the
list for details. first. In this case, values that had
been entered remain as they are until
modified. When the cursor is at the
highest-order digit, it can move to the
higher layer using [t] switch.
30-130 26 WA320, 320PZ-6

3) As both monitoring codes are settled, the

2 ITEMS screen will be turned on.
a Holding and cancelling the monitoring
data:
Pressing [U] switch while the monitoring
is in progress holds the monitoring data
and [U] mark starts flashing.Pressing [U]
switch again restores the active state.
4) Display data for 2 items simultaneous

monitoring
a The 2 items simultaneous monitoring
screen displays the following information.
A: Monitoring code 1
1: Monitoring data 1 (including the unit
used)
B: Monitoring code 2
2: Monitoring data 2 (including the unit
used)
a See the Real-time monitoring code list
for details.
WA320, 320PZ-6 30-130 27

Real-time monitoring codes table

a Use this page in next page and a spread.
MONITOR PANEL [Machine monitor system]
Monitoring item Displayed item Data display range

No. Monitoring code
(*1) (*2) (*3)
1 20200 Monitor software No. VERSION Alphanumerals
2 20221 Application version No. VERSION (APP) Numerals
3 20222 Data version No. VERSION (DATA) Numerals
4 01001 Engine speed ENG SPEED 0 4000
5 40012 Travel speed SPEED 0.0 50.0
6 04202 Fuel level FUEL SENSOR 0 100
7 04200 Fuel level FUEL SENSOR 0.00 5.00
8 04103 Coolant temperature COOLANT TEMP 40 210
9 04408 HST oil temperature HST OIL TEMP 24 131
10 04409 HST oil temperature HST OIL TEMP 0.00 5.00
11 30201 Front brake oil temperature F BRAKE OIL 24 131
12 30204 Front brake oil temperature F BRAKE OIL 0.00 5.00
13 04302 Charge level ALTERNATOR R 0.0 30.0
14 40200 Small lamp voltage SMALL LAMP 0.0 30.0
15 06001 Boom angle BOOM ANG -----
16 06003 Boom angle BOOM ANG -----
17 40400 Boom bottom pressure BOOM BTM PRESS -----
18 40402 Boom bottom pressure BOOM BTM PRESS -----
30-130 28 WA320, 320PZ-6

a Use this page in front page and spread.
Unit
Contents of display in normal state Remarks
(*4)
Condition
As per software No. 3rd 10th digits from right of part No. are displayed.
display
Condition
As per software application version No.
display
Condition
As per software data version
display
Low idle : 800 850 rpm

rpm Data are obtained from HST controller.
High idle: 2,200 2,300 rpm
F1/R1: 4.0 7.6 km/h

Shown value is max. speed in each speed range.
F2/R2: 13.0 18.7 km/h
km/h Value of F1/R1 is speed when travel speed con-
F3/R3: 18.7 23.6 km/h
F4/R4: 38.0 44.6km/h trol dial is at min. speed position.
0 100% (Depends on fuel level) %
Gauge FULL (100%, 10 z): 0.31 V

Gauge 1/2 (50%, 31.1 z): 0.86 V When sensor is disconnected or has hot-short: Gauge
Gauge 1/4 (25%, 46.8 z): 1.17 V V EMPTY
Caution (80 z): 1.75 V When sensor has ground fault: Gauge FULL
Gauge EMPTY (0%, 85 z): 1.82 V
Engine coolant temperature: Max. 102C

Depends on machine condition (C) C
Data are obtained from engine controller.
Depends on machine condition (C) C Overheat: 105C
Gauge enters red range(105C): 2.07 V When sensor is disconnected or has hot-short: Gauge MIN
V
(80C): 2.91 V When sensor has ground fault: Gauge MAX
Depends on machine condition (C) C
(120C): 1.62 V
V
1(80C): 2.91 V
Depends on machine condition (0.0 30 V) V
Depends on machine condition (0.0 30 V) V
----- deg ()
----- V
a No use these items.
----- MPa
----- V
WA320, 320PZ-6 30-130 29

Monitoring item Displayed item Data display range

No. Monitoring code
(*1) (*2) (*3)
19 40500 Boom head pressure BOOM HEAD PRES -----
20 40501 Boom head pressure BOOM HEAD PRES -----
21 40600 Calibration pressure CAL PRESS -----
22 40800 Weight calculated by load meter MES LOAD -----
23 30802 Rotary switch setting condition SW1, SW2, SW3 F, F, F
24 30904 DIP switch setting condition SW5-1, SW5-2 ON/OFF, ON/OFF
28 40900 Input signal D_IN_0-7 D-IN--0------7 See separate table.
37 40925 Output signal D_OUT_0-3 D-OUT-0--3 See separate table.
*1: All items, including ones for which sensors are not installed on some models and optional components,
are displayed.
*2: Abbreviated as number of characters is limited.
*3: A number out of the display range is displayed as -----.
*4: If a unit is necessary, the SI unit is used.
30-130 30 WA320, 320PZ-6

Unit
(*4)
----- MPa
----- V
a No use these items.
----- MPa
----- t
Condition
a Do not move from initial position.
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
WA320, 320PZ-6 30-130 31


Monitoring Input/Output
No. Displayed item Contents of ON/OFF switch
code signal
D-IN-0 Headlamp Headlamp lighting = ON (24 V)/OFF (OPEN)
D-IN-1 Cooling fan reverse switch Switch = ON (24 V)/OFF (OPEN)
D-IN-2 Starting switch C Starting motor operation = ON (24 V)/OFF (OPEN)
D-IN-3
1 40900 D-IN-4
D-IN-5
Multi-coupler solenoid (Machine with
D-IN-6 Multi-coupler solenoid = ON (24 V)/OFF (OPEN)
optional multi-coupler spec.)
D-IN-7
ECSS switch
D-IN-8 ECSS switch = ON (24 V)/OFF (OPEN)
(Machine with optional ECSS spec.)
Cooling fan automatic reverse setting = ON (24 V)/
D-IN-9 Cooling fan automatic reverse switch
OFF (OPEN)
D-IN-10
2 40901 D-IN-11
D-IN-12 Right winker Right winker lighting = ON (GND)/OFF (OPEN)
D-IN-13 Left winker Left winker lighting = ON (GND)/OFF (OPEN)
D-IN-14 U switch Pressing switch = ON (24 V)/OFF (OPEN)
D-IN-15 t switch Pressing switch = ON (24 V)/OFF (OPEN)
D-IN-16 Brake oil pressure Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-17
D-IN-18
D-IN-19
3 40902
D-IN-20 Air cleaner clogging No clogging = ON (GND)/OFF (OPEN)
D-IN-21
D-IN-22
D-IN-23
D-IN-24 HST filter clogging Clogging detection = ON (GND)/OFF (OPEN)
D-IN-25
D-IN-26 Parking brake Resetting parking brake = ON (GND)/OFF (OPEN)
D-IN-27 Engine coolant level Normal coolant level = ON (GND)/OFF (OPEN)
4 40903 D-IN-28 Omission of applying parking brake Resetting parking brake = ON (GND)/OFF (OPEN)
D-IN-29 Engine oil level Normal oil level = ON (GND)/OFF (OPEN)
Normal emergency steering Low emergency steering pressure = ON (GND)/OFF
D-IN-30
(Machine with optional emergency steering) (OPEN)
D-IN-31
*: 1 is displayed when ON and 0 is displayed when OFF.
30-130 32 WA320, 320PZ-6


code signal
D-IN-32
D-IN-33
D-IN-34 High beam (Dimmer switch) High beam = ON (GND)/OFF (OPEN)
Omission of applying parking brake
D-IN-35 Resetting parking brake = ON (GND)/OFF (OPEN)
(dummy)
5 40904
D-IN-36 Parking brake (dummy) Resetting parking brake = ON (GND)/OFF (OPEN)
D-IN-37 [>] switch Pressing switch = ON (GND)/OFF (OPEN)
D-IN-38 [<] switch Pressing switch = ON (GND)/OFF (OPEN)
Low steering pressure (Machine with
D-IN-39 Oil pressure reduction = ON (GND)/OFF (OPEN)
optional emergency steering spec.)
D-OUT-0 Alarm buzzer Output ON = ON (24 V)/OFF (OPEN)
D-OUT-1
6 40925 D-OUT-2 Backup alarm/lamp relay Output ON = ON (24 V)/OFF (OPEN)
ECSS solenoid relay
D-OUT-3 Output ON = ON (24 V)/OFF (OPEN)
(Machine with optional ECSS spec.)
*: 1 is displayed when ON and 0 is displayed when OFF.
WA320, 320PZ-6 30-130 33

HST [HST controller system]

Monitoring Real-time monitoring item Displayed item Data display range
No.
code (*1) (*2) (*3)
1 20201 Software No. VERSION
2 20223 Application version No. VERSION (APP)
3 20224 Data version No. VERSION (DATA)
5 40978 Output signal D_OUT_0-7 D-OUT-0------7 See separate table.
6 40979 Output signal D_OUT_8-15 D-OUT-8-----15 See separate table.
7 40980 Output signal D_OUT_16-23 D-OUT-16----23 See separate table.
8 41600 Engine mode ENGINE MODE 0/2
9 32600 HST oil pressure HST PRESS 0.0 500.0
10 32601 HST oil pressure HST PRESS 0.001 5.000
11 80000 Motor 1 output command value MOTOR SOL DIR 0 1000
12 81000 Clutch output command value CLUTCH SOL DIR 0 1000
13 41400 Fan output command value FAN EPC DIR 0 1000
14 93400 Fan reverse switch input FAN REVERSE SW 0/2/1
15 40013 Travel speed SPEED (HST) 0 50.00
16 31400 Output shaft speed T/M SPEED : OUT 0 32767
17 31404 Output shaft speed T/M SPEED : OUT2 0 32767
18 95400 Throttle correction command output THROTTLE MOD 100 100
19 44200 Throttle quantity upper limit value output THROT LIMIT UP 0.0 100.0
20 44201 Throttle quantity lower limit value output THROT LIMIT LO 0.0 100.0
21 43504 Automatic warm-up cancel flag WARM-UP CANCEL 0/1
30-130 34 WA320, 320PZ-6


Unit
(*4)
As per software No. Condition display
As per software application version No. Condition display
As per software data version Condition display
Condition display
Condition display
Condition display
Condition display
0 Condition display 0 is always displayed.
Low-pressure relief pressure: 2.5 2.8

MPa
High-pressure cutoff pressure: 43.1 46.6
Low-pressure relief pressure: 0.667 0.687
V
High-pressure cutoff pressure: 3.373 3.607
Above 10.5 km/h in 3rd or 4th gear speed: 0 mA
mA
Other than above: 100 600 mA (Depends on control)
When clutch is engaged: 670 mA
When clutch is disengaged (Above 10.5 km/h in 3rd or mA
4th gear speed): 0 mA
0 1000 mA
Fan rotation direction is being reversed: 800 mA mA
Fan is rotating in reverse: 0 mA
Switch position, forward: 0
Switch position, automatic reverse: 2 Condition display
Manual reverse switch is being operated: 1
Depends on travel speed. km/h Not used
0 km/h = 0 min-1
10 km/h = 754 min-1
min-1 is SI unit of rotation speed.
20 km/h = 1509 min-1 min-1
(1 min-1 = 1 rpm)
30 km/h = 2264 min-1
40 km/h = 3019 min-1
0% % 0% is always displayed.
Ordinary: 100%
%
Forward travel in S mode: 50 100%
0% % 0% is always displayed.
Directional lever in N, stopped: 0 (OFF)

Condition display
Other than above: 1 (ON)
WA320, 320PZ-6 30-130 35


Monitoring Real-time monitoring item Displayed item Data display range
No.
code (*1) (*2) (*3)
22 99100 Parking brake switch signal PARKING A/B 11/00/10/01
23 04302 Alternator R voltage signal ALTERNATOR 0.0 30.0
24 99200 Travel speed control dial SPEED POT 0.0 50.0
25 99201 Travel speed control dial SPEED POT 0.001 5.000
26 80200 Traction level setting TRACTION 0 100
27 99101 Forward-Reverse selector switch FNR signal MULTI FNR 100/010/001
28 99300 Machine status HST STATUS 06
29 99301 Clutch status CLUTCH STATUS 04
30 99302 Forward-Reverse recognition TRAVEL F/R F/R
30-130 36 WA320, 320PZ-6


Unit
(*4)
Parking brake position (High): 00
(Middle): 10 Condition display
(Low): 11
0 30 V V
4.0 13.0 km/h (Depends on travel speed control dial

km/h
position)
0.9 4.1 V (Depends on travel speed control dial posi-
V
tion)
Traction level setting (When stopped)
When traction level A is set: 84% Display is as shown at left, regardless of traction control
%
When traction level B is set: 74% switch position.
When traction level C is set: 64%
100: F, 010: N, 001: R
Condition display
ON/OFF refers to each bit.
Stopped: 0
Forward travel (Directional lever in F): 1
Reverse travel (Directional lever in R): 2
Forward travel, lever in R: 3 Condition display
Reverse travel, lever in F: 4
Forward travel, lever in N: 5
Reverse travel, lever in N: 6
Clutch condition
Engaged o Being prepared for disengaging: 0
Disengaged (During high-speed travel in 3rd, 4th
speed range): 1
Disengaged o Engagement is being modulated Condition display
(During deceleration in 3, 4th speed range): 2
Completion of engagement (During low-speed travel
in 1st, 2nd speed range or 3rd, 4th speed range)
Being disengaged: 4
Forward travel: F Previous condition is displayed while machine is
Condition display
Reverse travel: R stopped
*1: All items, including ones for which sensors are not installed on some models and optional components,
are displayed.
*2: Abbreviated as number of characters is limited.
*4: If a unit is necessary, the SI unit is used.
WA320, 320PZ-6 30-130 37


codes signal
D-IN-0 FNR (Directional) lever F (Forward) F (Forward) = ON (24 V)/OFF (OPEN)
D-IN-1 FNR (Directional) lever N (Neutral) N (Neutral) = ON (24 V)/OFF (OPEN)
D-IN-2 FNR (Directional) lever R (Reverse) R (Reverse) = ON (24 V)/OFF (OPEN)
Right FNR (directional) switch selector

D-IN-3 Pressing switch = ON (24 V)/OFF (OPEN)
switch
1 40977
D-IN-4 Traction control switch Pressing switch = ON (GND)/OFF (OPEN)
D-IN-5
D-IN-6
D-IN-7
D-OUT-0
D-OUT-1
D-OUT-2
D-OUT-3
2 40978
D-OUT-4
D-OUT-5
D-OUT-6
D-OUT-7
D-OUT-8
D-OUT-9
D-OUT-10
D-OUT-11
3 40979
D-OUT-12
D-OUT-13
D-OUT-14 VIS Self-holding relay Output ON = ON (GND)/OFF (OPEN)
D-OUT-15 HST safety relay Output ON = ON (GND)/OFF (OPEN)
D-OUT-16 Motor 2 solenoid relay Output ON = ON (GND)/OFF (OPEN)
D-OUT-17 Fan reverse solenoid relay Output ON = ON (GND)/OFF (OPEN)
D-OUT-18 Fan reverse solenoid relay HST pump F solenoid = ON (24 V)/OFF (OPEN)
D-OUT-19 HST pump R solenoid (Reverse) HST pump R solenoid = ON (24 V)/OFF (OPEN)
4 40980
D-OUT-20
D-OUT-21
D-OUT-22
D-OUT-23
1 is displayed when ON and 0 is displayed when OFF.
30-130 38 WA320, 320PZ-6

ENG [Engine controller system]

Monitoring Monitoring items Displayed items Data display range Unit
No. Remarks
code (*1) (*2) (*3) (*4)
Status
1 20400 Hardware serial No. ECM S/N Arabic numerals
display
2 03200 Battery voltage POWER SUPPLY 0.0 480.0 V
3 01002 Engine speed ENG SPEED 0 4000 rpm
4 04104 Engine coolant temperature COOLANT TEMP 40 210 C
5 04105 Engine coolant temperature sensor voltage COOLANT TEMP 0.00 5.00 V
6 36400 Common rail pressure RAIL PRESS 0 400 MPa
7 36402 Common rail pressure sensor voltage RAIL PRESS 0.00 5.00 V
8 37400 Atmospheric pressure AMBIENT PRESS 99.9 999.9 kPa
9 37402 Atmospheric pressure sensor voltage AMBIENT PRESS 0.00 5.00 V
10 18500 Boost temperature CHG TEMP 50 200 C
11 18501 Boost temperature sensor voltage CHG TEMP 0.00 5.00 V
12 36500 Boost pressure CHG PRESS-A 99.9 999.9 kPa
13 36502 Boost pressure sensor voltage CHG PRESS-A 0.00 5.00 V
14 18700 Engine output torque OUTPUT TORQUE 24000 24000 Nm
15 36700 Equivalent torque TORQUE RATIO 0 100 %
16 31706 Final accelerator position FINAL THROTTLE 0 100 %
17 37300 Momentary fuel consumption FUEL RATE 0.0 999.9 1/h
18 18600 Final injection volume command (in weight) INJECT COMMAND 0 1000 mg
19 36300 Final injection timing command TFIN INJECT TIMING 180.0 180.0 CA
20 31701 Accelerator pedal position THROTTLE POS 0 100 %
21 31707 Accelerator pedal sensor voltage THROTTLE POS 0.00 5.00 V
Status
22 18300 Idle validation signal IVS 1 ON/OFF
display
Status
23 18301 Idle validation signal IVS 2 ON/OFF
display
24 18900 Engine controller internal temperature ECM IN TEMP 40 210 C
Final common rail pressure command
25 36200 PRESS COMMAND 0 400 MPa
PFIN
Status
26 17500 Selection of engine mode POWER MODE 04
display
Status
27 18800 WIF sensor stats WATER IN FUEL ON/OFF
display
Incoming value is
displayed as is Status
28 00400 Name of selected model (upper 8 digits) MACHINE ID (H)
(Upper 8 digits of display
16 characters)
Incoming value is
displayed as is Status
29 00401 Name of selected model (lower 8 digits) MACHINE ID (L)
(Lower 8 digits of display
16 characters)
Incoming value is
Status
30 20216 Build version BUILD VER displayed as is
display
(8 characters)
Incoming value is
Status
31 20217 Calibration data version CAL VER displayed as is
display
(8 characters)
*1: All items are displayed including those for which sensors are not provided depending on the given
model or option.
*2: Abbreviated expression is employed because of number of characters usable is restricted.
*4: SI units alone are employed whenever a unit is needed.
WA320, 320PZ-6 30-130 39

5. Engine reduced-cylinder function (CYLIN- 3) Selecting a cylinder to be reduced

DER CUT-OUT) Using [<] or [>] switch, select a cylinder to
The engine reduced-cylinder function denotes be reduced from No. 1 No. 6 cylinders
setting the injector of a single cylinder or two or and then settle the selected cylinder using
more cylinders to electrically no injection state [U] switch.
and turns on the operation on reduced-cylinder a The cylinder to be reduced is selectable
condition. When any cylinders of the engine while the engine is run.
were suspected for abnormal output (combus- a Any number of cylinders can be reduced
tion), this approach is used to single out the a single unit or two or more units.
failed cylinder. q [>] switch: Advances the cursor right-
1) Selecting the menu ward
Display the CYLINDER CUT-OUT screen q [<] switch: Advances the cursor left-
from the menu screen of Service mode. ward
q [U] switch: Settles the cylinder to be
reduced (the cursor starts flashing
after the settlement)
q [t] switch: Restores the CYLINDER
CUT-OUT screen
2) Displaying sub menu

Press [U] switch while the menu i s
selected to display the sub menu.
a As the reduced-cylinder command is

issued from the engine controller to the
cylinder to be reduced, the bottom of the
stopped cylinder number turns to black.
30-130 40 WA320, 320PZ-6

4) Cancelling a reduced cylinder 2) Pressing [U] switch sets up the no injec-

Using [<] or [>] switch, select the currently tion cranking.
stopped cylinder and then press [U] a If this screen does not appear as [U]
switch to cancel the reduced-cylinder switch is hit, a communication error should
command from the engine controller. The be suspected.
black display will disappear.
a If the no injection cranking is selected as

6. No injection cranking function the engine is running, the engine stop
The machine monitor is equipped with the instruction screen will appear.
function capable of lubricating the engine a In such case, stop the engine once and
through no injection cranking. When a machine then do the set up again.
has been stored for a long time, this function is
used to lubricate the engine prior to its restart
in order to prevent its wear or damages out of
oil.
The no injection cranking must be set up while
1) Selecting menu
Display the NO INJECTION screen from
WA320, 320PZ-6 30-130 41

7. Adjustment function (TUNING) 7-1. Adjustment of interval of fan automatic

The machine monitor implements initial setting reverse operation
after disassembly or replacement of the trans- a This function is used to change the inter-
fer, or after replacement or addition of sensor, val of the forward and reverse operations
HST pump, HST motor and EPC valve or con- of the fan when the fan automatic reverse
troller. Through the initial setting, the machine operation is selected.
monitor corrects and adjusts the installation a The interval of the fan automatic reverse
error or manufacturing variations of individual operation is adjustable in the range from
parts. 0.1 h (6 minutes) to 200 h. It must be set
a Adjustment function to at least twice the continuance of the fan
automatic reverse operation, however,
Item Code
Adjustment item and cannot be set shorter than twice.
No. No.
a When the machine is delivered, the inter-
Adjustment of interval of fan auto-
7-1 03 val of fan automatic reverse operation is
matic reverse operation
set to 2.0 h.
7-2 04
Adjustment of continuance of fan a When the machine is delivered, the con-
automatic reverse operation tinuance of the fan automatic reverse
Adjustment of lift arm angle sensor operation is set to 2 minutes.
7-3 05
(upper) (for load meter) (*) 1) On the service mode menu screen, dis-
Adjustment of lift arm angle sensor play the TUNING screen.
7-4 06
(lower) (for load meter) (*)
Adjustment of ECSS operation travel
7-5 07
speed
* This menu is displayed but it is not used.
a The items which prohibit use

The setting of following items (code: 01,
02) are not changed because of prohibi-
tion of use.
2) Hold down the [U] switch for at least 5

seconds to display the next screen.
a Do not use this item.
30-130 42 WA320, 320PZ-6

3) With the [<] and [>] switches, select 03: 7-2. Adjustment of continuance of fan automatic
FAN REV PD screen. reverse operation
a This function is used to change the contin-
uance of the reverse operation when the
fan automatic reverse operation is
selected.
a The continuance of the fan automatic
reverse operation is adjustable in the
range from 0.5 minutes to 10 minutes. It
must be set to below 1/2 of the interval of
the fan automatic reverse operation, how-
ever, and cannot be set longer than 1/2.
a When the machine is delivered, the con-
tinuance of fan automatic reverse opera-
tion is set to 2.0 minutes.
a When the machine is delivered, the inter-
4) Press the [U] switch to settle. val of the fan automatic reverse operation
a If the [U] switch is pressed, the screen is set to 2.0 h.
to adjust the interval of fan automatic 1) On the service mode menu screen, dis-
reverse operation is displayed. play the TUNING screen.
5) With the [<] and [>] switches, select an
interval in the range from 0.1 to 200
(Unit: h).
6) Press the [t] switch to settle the setting.
a The selected interval of fan automatic
reverse operation is not changed to a
value less than twice the continuance
of the fan automatic reverse operation.

WA320, 320PZ-6 30-130 43

3) With the [<] and [>] switches, select 04: 7-5. Adjustment of ECSS operation travel speed
FAN REV PD screen. (if equipped)
a This function is used to adjust the ECSS
operation/reset travel speed.
a The initial ECSS operation travel speed is
5 km/h.
a The ECSS reset travel speed is the ECSS
operation travel speed minus 1 km/h.
Example: q If the ECSS operation travel
speed is 5 km/h, the ECSS
reset travel speed is 4 km/h.
q If the ECSS operation travel
speed is 8 km/h, the ECSS
reset travel speed is 7 km/h.
1) Display the TUNING screen from the
4) Press the [U] switch to settle.
a If the [U] switch is pressed, the
screen to adjust the continuance of
fan automatic reverse operation is
displayed.
5) With the [<] and [>] switches, select a con-
tinuance in the range from 0.5 to 10
(Unit: minute).
6) Press the [t] switch to settle the setting.
a The selected continuance of fan auto-
matic reverse operation is not
changed to a value longer than 1/2 of
the interval of the fan automatic
reverse operation.
7-3. Adjustment of lift arm angle sensor (upper)

(Load meter specification)
a This item is not used.
7-4. Adjustment of lift arm angle sensor (lower)

(Load meter specification)
a This item is not used.
30-130 44 WA320, 320PZ-6

3) Select 07: ECSS SPEED with [<] or [>] 8. Maintenance monitoring function
switch. The maintenance function offers the following
capabilities in the maintenance of filters and
oils.
q Change of maintenance interval time
q Selection between enabling or disabling
timer by item
q Setting of a default value
q Selection between enabling or disabling
timer for items
8-1. Changing maintenance interval time
1) Display the MAINTENANCE MONITOR
screen from the menu screen of Service
mode.
4) Press [U] switch to settle.

a If the selection is settled, the ECSS
operation travel speed adjustment
screen appears.
2) Press [U] switch to display 01: ENG OIL

screen.
a The lower left side space indicates the
time remained up to the replacement.
a The lower right side space indicates the
cumulative replacement frequencies.
5) To increase the ECSS operation travel 3) Using [<] or [>] switch, select the item for
speed, press [>] switch. which the maintenance interval is to be
a The operation travel speed is changed from the following.
increased 1 km/h by 1 operation of
the switch.
a The operation travel speed can be
adjusted to a maximum of 8 km/h.
6) To decrease the ECSS operation travel
speed, press [<] switch.
a The operation travel speed is
decreased 1 km/h by 1 operation of
the switch.
a The operation travel speed can be
adjusted to a minimum of 5 km/h.
7) If the operation travel speed is set to a
desired value, press [t] switch to finish
setting.
WA320, 320PZ-6 30-130 45

List of maintenance items
Indication of items on the Replacement

Item ID No.
character display interval time (H)
Engine oil 01 ENG OIL 500
Engine oil filter 02 ENG FILT 500
Fuel pre-filter 41 FUEL P FILT 500
Fuel filter 03 FUEL FILT 1000
Corrosion resistor 06 CORR RES 1000
Transfer oil 25 TRANSF OIL 1000
HST oil filter 26 HST FILT 1000
Hydraulic oil filter 04 HYD FILT 2000
Hydraulic oil 10 HYD OIL 2000
Axle oil 15 AXLE OIL 2000
4) Settle the target items of interval change a When you have entered a wrong value to
by use of [U] switch. a position except the highest-order digit,
move to the highest-order digit using [t]
switch and repeat the procedure from the
first. In this case, the value that had been
entered remains as it is until modified.
When the cursor is at the highest-order
digit, move to the higher layer using [t]
switch.
5) Maintenance interval time change proce-

dure
1] This cursor is located at the highest-
order digit. Pressing [<] or [>] switch
changes the value of this digit in the
range of 0 9.
value.
3] Set the values up to the lowest-order
digit in the same order and then press
[U] switch.
q When the input interval time is within
the setting range: The screen
changes to the check screen.
q When the entered interval time is out
of the setting range: The entered
interval time does not replace the cur-
rent value and the input screen will be
restored.
a The shortest interval time value is 50 h.
30-130 46 WA320, 320PZ-6

6) Select YES or NO using [<] or [>] a When Timer by item is disabled, the
switch. order of display becomes OFF o ON.
a The selected cursor will start flashing. If a The default display is ON.
Y ES i s s ele cted and [t] s witc h i s
maintenance interval change item screen
is restored.
a When an interval time is changed, the
timer remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set Elapsed time from the last replace-
ment
2) Press [U] switch from this state.
a If Timer by item is disabled, OFF will be
displayed in the upper column.
8-2. Selection between enabling or disabling timer

by item
1) Pressing [<] or [>] switch from 8-1-3) Inter-
val time change screen displays the a If Timer by item is enabled, ON will be
Selection between enabling or disabling displayed in the upper column.
timer by item screen.
a When Timer by item is enabled, the
order of display is ON o OFF.
WA320, 320PZ-6 30-130 47

3) Select YES or NO using [<] or [>] 3) Press [U] switch from this state.
switch. 4) Select YES or NO using [<] or [>] switch.
a The selected cursor will start flashing. If a The selected cursor will start flashing. If
Y ES i s s ele cted and [t] switc h i s YE S is s elec ted a nd [ t] s witc h is
pressed, the information will be deleted. If pressed, the change will be enabled If
NO is selected and [t] switch is NO is selected and [t] switch is
pressed, deletion is cancelled and the pressed, the change will not be imple-
maintenance interval change item screen mented and the maintenance monitoring
is restored. screen will be restored.
a By default, the cursor is set to NO (cancel) a By default, the cursor is set to NO (cancel)
a An interval time is changed, the timer
remaining time is changed as shown
below.
q Timer remaining time = Interval time being
set Elapsed time from the last replace-
ment
8-3. Changing set default value.

1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
a If the default value setting is executed, all

the currently changed interval times are
returned to the default values. It is executed
on every item independent of whether or not
the function is enabled for a specific item.
a Timer remaining time shall be Default
value E lapsed time s ince the l ast
replacement.
a Executing the default value setting does
not affect the reset frequency. Namely, it
remains the same as before this operation
was executed.
2) Using [<] or [>] switch, select the INITIALIZE a Set enable for enable or disable of individ-
screen from the following table. ual items.
8-4. Selection between timer stop for all items and

enable by item
1) Press [U] switch from the MAINTE-
NANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
30-130 48 WA320, 320PZ-6

2) Using [<] or [>] switch, select the ALL 5) Press [U] switch from the ALL ITEMS o
ITEMS OFF OR ON screen from the fol- OFF screen or the ALL ITEMS o ON
lowing table. screen.
a When [U] switch is pressed from the ALL
ITEMS o OFF screen, OFF will be is dis-
played in the upper space.
3) Press [U] switch to display the ALL

ITEMS o OFF screen.
a When [U] switch is pressed from the ALL

ITEMS o ON screen, ON will be is dis-
played in the upper space.
6) Select YES or NO using [<] or [>]
switch.
YE S is s elec ted a nd [t] s witc h is
maintenance interval change item screen
is restored.
4) Press [<] or [>] switch when selecting the to prevent resetting error.
ALL ITEMS o ON.
WA320, 320PZ-6 30-130 49

7) As the timer stop for all items is executed: 3) Using [<] or [>] switch, select the item to
a The timer function for all items is stopped be displayed from 1] 4] on the fuel con-
a n d t h e M A I N TE N A N CE M O NI TO R sumption ratio and average fuel consump-
screen is restored. tion screen.
a Setting for individual items is also disabled. 1] Fuel consumption ratio and average
a If cancelled: The operation is cancelled fuel consumption screen
a n d t h e M A I N TE N A N CE M O NI TO R a The upper column displays fuel con-
screen is restored. sumption [L/km or L/mile] per 1 km (or
8) When timer enable for all items is executed: 1 mile) from the last resetting.
a Interval time being set for all items is exe- q Above value is computed from the
cuted to the set value before disabled fuel consumption ratio and travel dis-
i nd e p e nd e n t o f wh e th e r o r n ot i t i s tance (odometer distance).
enabled or disabled for a specific item. a The lower column displays the aver-
a The timer remaining time is reset. (The age fuel consumption [L/h] from the
reset frequency remains the same as last resetting.
before the resetting.) a Calculation is done only for the dura-
a The MAINTENANCE MONITOR screen is tion in which the engine is run.
restored.
a Setting for individual items is also enabled.
a If cancelled: The operation is cancelled
a n d t h e M A I N TE N A N CE M O NI TO R
screen is restored.
9. Operating information display function

It is a fuel consumption-related function and
displays the following information.
q Fuel consumption ratio and average fuel
consumption
q Cumulative fuel consumption and travel
distance
q Cumulative fuel consumption and elapsed
time 2] Cumulative fuel consumption and travel
1) Selecting menu distance
Display the OPERATION INFO screen a The upper column displays the cumu-
from the menu screen of Service mode. lative fuel consumption [L] from the
last resetting.
q The counting is stopped at 99999.9,
the upper limit.
a The lower column displays the travel
distance [km or mile] from the last
resetting.
q The unit km or mile shall be selected
depending on that used on the odom-
eter.
the upper limit.
a Calculation is done only for the dura-
tion in which the engine is run.
2) Press [U] switch to display the fuel con-

sumption ratio and average fuel consump-
tion screen.
30-130 50 WA320, 320PZ-6

4) Deleting display data

a Data on screens 3) 1] to 3] allow deletion.
a Select a desired item and then delete it
using [U] switch.
a Use [t] switch when canceling deletion of
data.
3] Cumulative fuel consumption and

elapsed time
a The upper column displays the cumu-
lative fuel consumption [L] from the
last resetting.
the upper limit. 5) Setting gain correction
a The lower column displays the a Gain correction denotes the function of
elapsed time [h] from the last reset- correcting gain to cumulative fuel con-
ting. sumption.
q The counting is stopped at 99999.9, a Gain correction is reflected 3) 1] to 3].
the upper limit. 1] After deleting data (RESET screen),
a Calculation is done only for the dura- press [<] or [>] switch to display the
tion in which the engine is run. current set value.
2] Pressing [U] switch displays the cor-

rection screen.
a Default value: 0.0%
a This setting allows correcting the
cumulative fuel consumption in the
range of 50.0 to +50.0.
3] Move the cursor to [+] or [].
4] Pressing [<] or [>] switch alternately
displays [+] and [].
5] Press [U] switch to settle [+] or [].
a The cursor moves to the highest-
order digit of the set value.
6] Pressing [<] or [>] switch changes the
value of this digit in the range of 0 9.
WA320, 320PZ-6 30-130 51


value.
8] Set the values up to the lowest digit in
the same order as above and then
press [U] switch to settle.
a As the selection is settled, the pre-
ceding screen is restored.
a If [t] switch is pressed before finish-
ing entering, the cursor moves to the
[+] and [] position. In this case, the
value remains unchanged. Pressing
[t] switch again restores the preced-
ing screen.
a If the value is not in the 50 +50
range, pressing [U] switch at the low-
est digit just moves the cursor the [+]
and [] position and the value
remains as it is.
30-130 52 WA320, 320PZ-6

10. OPTIONAL SELECT function

a The procedure for setting an option is as follows; Set the option and turn the starting switch OFF. After
the power for each controller is turned OFF (about 15 seconds), turn the starting switch ON again, and
the option is effective.
a Before setting an option, check that the machine model has been selected. (Select the machine model
before setting the option.)
Optional device installation setting table

Display in Setting at
No. Item Contents of selection Remarks
English monitor delivery
1 Tire type TIRE TYPE 20.5 Keep 20.5
2 Emergency steering EMERG S/T NO ADD If equipped, select ADD.
Right FNR (directional)
3 FNR NO ADD If equipped, select ADD.
switch
Keep to ADD normally.
NO ADD is selected, ECO
4 ECO lamp operation ECO LAMP ADD
lamp in machine monitor is kept
turned OFF.
If not installed optionally, select
5 ECSS E. C. S. S. ADD
NO ADD.
REVERSE If fan reverse function is not
6 Reverse fan ADD
FAN installed, select NO ADD.
MECHA: Mechanical
7 Parking brake PKG BRAKE MECHA Keep to MECHA
ELEC: Electric
Keep to 0 normally.
If number other than 0 is
selected, only travel speed
9 Tire size correction TIRE SIZE 0%
display in machine monitor
increases or decreases
according to selected number.
11 Travel speed unit SPEED (UNIT) km/h
Can be changed in only non-SI
specification. For contents of
change, see Remarks
column. NO ADD: (*1)
Selection of travel
To change travel speed display ADD: (*2)
12 speed/engine speed RPM OPT NO ADD
to engine speed display in ADD o NO ADD: (*3)
display on main screen
operator mode, select ADD. NO ADD o ADD: (*4)
Note: Do not select ADD in
region where display of travel
speed is obliged by law.
Selection of engine Keep to ADD normally.
ADD: (*5)
speed/travel speed on If NO ADD is selected,
NO ADD: (*6)
13 normal screen of RPM/SPEED ADD Engine speed or travel speed
ADD o NO ADD: (*7)
character display or are not displayed on character
NO ADD o ADD: (*8)
non-display display.
Reference: Item Nos. 8 and 10 are missing.
*1: Selection of speed/engine speed is not displayed in operator mode.

*2: Selection of speed/engine speed is displayed in operator mode (Tachometer can be displayed as main
item).
*3: Fixed to speedometer.
*4: Setting at previous ADD or initial setting.
*5: Travel speed/rpm on character display: Displayed/Not displayed is displayed in operator mode.
*6: Travel speed/rpm on character display: Displayed/Not displayed is not displayed in operator mode.
*7: Not displayed.
*8: Setting at previous ADD or initial setting.
WA320, 320PZ-6 30-130 53

1) Display the OPTIONAL SELECT screen 10-1. Option setting/not setting selection
from the menu screen of Service mode. a Among the items included in the list of installed
optional devices and their setting, the option
setting/not setting selection applies to the fol-
lowing items.
a If the options are not selected, the option non-
selection screen (NO ADD) is displayed.
2) Hold down [U] switch for 5 seconds or

longer.
3) The 1: TIRE TYPE screen will appear.
a If the [t] switch is pressed, the
screen returns to the OPTIONAL
SELECT screen. a If the options are selected, the option selected
screen (ADD) is displayed.
a Be sure to start setting of each option

o n 1 : T IR E T Y P E s c r e e n . A ft e r a [U] switch allows alternately displaying the
changing or settling the option, set option non-selection screen and the option-
other items in order on the next 2: selected screen.
EMERG S/T screen and the following
screens. Reference: Details of the main items are shown
below.
30-130 54 WA320, 320PZ-6

10-2. Selection of optional tire type 10-4. Setting tire deflection option
a Select 1: TIRE TYPE from Optional device a Select 9: TIRE SIZE from the list of installed
installation setting table. optional devices and their setting.
Reference: This screen appears first when the a Pressing [U] switch sequentially displays
screen is changed from the OPTIONAL [@@]% in the following order.
SELECT screen. a The display progresses from +00 through 10.
a Each time [U] switch is pressed, the tire type Pressing [U] switch at this point returns the
changes from small to large. display to +00.
Selectable size: 20.5
a Select only 20.5 (Do not change) Order No.1 No.2 No.3 No.4 No.5 No.6 No.7
a If the tire type is changed, the operation accep- @@ +00 +02 +04 +06 +08 +10 +12
tance tone (peep) sounds.
Order No.8 No.9 No.10 No.11 No.12 No.13 No.14
@@ 02 4 6 8 10 12 +00
a As the display is switched, the sound (beep)

indicating acceptance of the operation will be
generated.
10-3. Selection of optional parking brake

a Select 7: PKG BRAKE from Optional device
installation setting table.
a Each time [U] switch is pressed, the parking
brake type changes.
S e l e c ta b l e i t e m : M E C H A ( M e c h a n i c a l :
Default), ELEC (Electric) 10-5. Storing option selection
a If the parking brake type is changed, the oper- 1) When the option selection was changed,
ation acceptance tone (peep) sounds. turn off the starting switch once to stop the
controller operation completely. (After turn-
ing off the starting switch, wait for 15 sec-
onds without doing any switch operation.)
2) The specified option selection is enabled
as the starting switch is turned on.
a Whenever an option selection is made, turn
off the starting switch once and then turn it
on again in approximately 15 seconds.
WA320, 320PZ-6 30-130 55

11. Machine serial number input function 12. Machine model select function
1) Display the MACHINE No. SET screen (MACHINE WA***)
from the menu screen of Service mode. a The setting of the machine model of the
machine monitor can be changed with the
machine model select function.
a If the machine monitor is initialized, per-
form the machine model select operation
first.
a If the machine model select operation is
performed, the setting of options is reset.
Accordingly, start with the option select
operation and select all the options.
12-1. Implementing the model change

1) Display the MACHINE screen from the
a The currently selected machine model is
2) Press [U] switch to display the MACHINE displayed on the lower line.
No. screen.
3) Enter the serial number according to the
a The cursor is positioned at the high-
est-order digit.
1] Pressing [<] or [>] switch increases or
decreases the value at the cursor
position. Select a desired value using
these switches.
2] Press [U] switch to settle the selec-
tion.
a The cursor moves to the digit situated
immediately on the right hand.
3] Set the values up to the lowest digit in
the same order as above and then 2) Hold down [U] switch for 5 seconds to
press [U] switch to settle. display the model selection screen.
a As the selection is settled, the imme-
diately preceding screen is restored.
a Pressing [t] switch while entry is taking
place will move the cursor the highest-
order digit. In this case, repeat entry
from the highest-order digit.
a If [t] switch is pressed while the cur-
sor is at the highest-order digit, the
immediately preceding screen will be
restored.
30-130 56 WA320, 320PZ-6

3) With the [<] and [>] switches, select the 14. Item that refers to SERVICE NEWS
machine model. Refer to SERVICE NEWS for the following
a Selectable models items.
q WA100 q Setting of service meter when machine
q WA150 monitor is exchanged.
q WA200 q Setting of odometer when machine moni-
q WA250 tor is exchanged.
q WA270
q WA320
a If wrong model and tire are set,
machine does not work correctly.
a Press [t] switch when stopping the model
selection.
a As the operation is stopped, the sound
(beep) indicating acceptance of the opera-
tion will be generated, restoring the
MACHINE screen.
4) With the [U] switch, settle the changed
machine model and tire size.
a As the selection is settled, the sound
(beep) indicating acceptance of the opera-
tion will be generated, restoring the
MACHINE screen.
a Check that the desired machine model is
displayed on the machine model select
screen.
12-2. Storing model change

1) When the model change was done, turn off
the starting switch once to stop the controller
operation completely. (After turning off the
starting switch, wait for 15 seconds without
doing any switch operation.)
2) The model being selected as the starting
switch is turned on is validated.
a Whenever a model change was done, turn
off the starting switch once and then turn it
on again in approximately 15 seconds.
13. Initialize function

This function is used only in the factory. It is,
therefore, not used for a service purpose.
WA320, 320PZ-6 30-130 57

SEN04187-01 Pm clinic inspection chart
Pm clinic inspection chart 1 WA320-6 Serial No. 70001 and up
Machine serial No.

Hours inspection Engine serial No. SAA6D107E-1 #
Work order No. Date of execution Service Meter Serviceman

Year: Month: Day: h
Questions asked to operator, walk around inspection
Ambient temperature
Was there any abnormality before inspection started?
Max. C
Min. C
Altitude m
Max. coolant temp. (During operation) Max. HST oil temp. (During operation)
Segment color W G G G G R R Segment color G G G G G R R
1 2 3 4 5 6 7 1 2 3 4 5 6 7
a If the machine is cold, warm it up fully. <>: Reference value

Standard Service limit Measurement
Item Conditions Unit value for new Pass Fail
value results
machine
Low idle 800 850 800 850
High idle 2,200 2,300 2,200 2,300
Engine speed HST stall rpm 2,110 2,310 2,010 2,300
Hydraulic stall 2,050 2,250 1,950 2,300
Engine
Full stall (HST stall + hydraulic stall) 1,830 2,160 1,730 2,260
Blow-by kPa Max. 0.98 1.96
pressure At rated output {mmH2O} {Max. 100} {200}
Min. 0.29 0.25
High idle {Min. 3.0} {2.5}
MPa
Oil pressure SAE15W-40 {kg/cm2}
Low idle Min. 0.10 0.07
{Min. 1.0} {0.7}
a Before starting the inspection, check that the machine does not move when the directional lever is placed in position.
k When measuring the transfer clutch control pressure, carry out the measurement at a place where the machine can travel
safety at a speed of more than 10 km/h.
Directional lever: F
High-pressure Speed selector 42.9 45.3 41.1 45.3
cut-off pressure switch: 2nd {438 462} {420 460}
Traction control
switch: ON
Low-pressure
relief pressure
(work equip- Directional lever: N
3.0 3.2 2.9 3.2
ment PPC cir- {31 33} {30 33}
cuit basic
pressure) Engine:
Full throttle
Hydraulic Directional lever: N 3.0 3.2 2.9 3.2
Servo piston Brake: released {31 33} {30 33}
oil temp.: MPa
HST
control pres-
sure 45 55C Directional lever: N {kg/cm2} Max. 0.6 Max. 0.6
Brake: pressed {Max. 6} {Max. 6}
Directional lever: For-
ward and reverse
Gear speed selector
Servo piston switch: 1st
3.0 3.2 2.8 3.2
actuation pres- Travel speed control
{31 33} {29 33}
sure dial: Min. side
Measure while driv-
ing at full throttle
(Approx. 5 km/h).
Transfer clutch Hydraulic oil Directional lever: F
control pres- temp.: Speed selector 3.0 3.2 2.9 3.2
{31 33} {30 33}
sure 45 55C switch: 3rd or 4th
30-130 58 WA320, 320PZ-6

Pm clinic inspection chart SEN04187-01
WA320-6 Serial No. 70001 and up

<>: Reference value
Standard Service limit Measurement
Item Conditions Unit value for new Pass Fail
value results
machine
Steering wheel Engine low idle 3.3 4.1 Max. 4.8

operating time sec.
Steering
Engine high idle 3.4 4.0 2.7 4.7

Lock frame with frame lock bar
Steering relief MPa 20.1 21.6 18.6 22.6
Engine high idle
pressure {kg/cm2} {205 220} {190 230}
Front right 0.9 1.1 Max. 0.6
Brake
Lining thick- Front left 0.9 1.1 Max. 0.6

Service brake mm
ness Rear right 0.9 1.1 Max. 0.6
Rear left 0.9 1.1 Max. 0.6
MPa 20.2 21.0 18.6 22.6
Relief pressure Bucket relief
{kg/cm2} {206 214} {190 230}
Raising time 5.2 6.2 Max. 8.6
Work equipment
Lift arm speed Engine high

idle Lowering time 3.0 4.0 Max. 5.3
Dumping time sec. 0.9 1.5 Max. 1.8
Bucket speed Tilting-back time
0.9 1.5 Max. 2.0
(At full stroke)
Engine Bucket cylinder mm/15 Max. 17 Max. 26

Hydraulic drift stopped min.
Lift cylinder Max. 20 Max. 30
Front axle
Axle
Check differential oil visually Must be no excessive metal

Rear axle particles
MEMO
WA320, 320PZ-6 30-130 59

SEN04187-01

2009 KOMATSU
All Rights Reserved
30-130 60
SEN04188-01
WA320-6
WA320PZ-6
WA320-6 70001 and up

40 Troubleshooting 40
100 Failure code table and fuse locations

Failure codes table.......................................................................................................................................... 2
Fuse locations................................................................................................................................................. 8
WA320, 320PZ-6 40-100 1

SEN04188-01 Failure codes table
Failure codes table 1
Failure Action Category of Reference

Troubled part Trouble Controller
code code record document No.
Mechanical
2G40ZG Brake Oil pressure reduction MON E03
system
Mechanical
6091NX HST filter Clogging MON E01
system
Mechanical
989FN1 Travel speed Overrun alarm MON E02
system
Mechanical
AA1ANX Air cleaner Clogging MON E01
system
Electrical
AB00L6 Alternator R system Hot short MON E01
system
Ground fault/Disconnec- Electrical Troubleshoot-
AB00MA Alternator R system MON E03 ing by failure
tion/Low charge level system
code (Display
Mechanical of code), Part 1
B@BAZG Engine Oil pressure reduction ENG E03
system SEN04190-00
Mechanical
B@BAZK Engine oil Low oil level MON E01
system
Mechanical
B@BCNS Engine Overheat ENG E02
system
Mechanical
B@BCZK Engine Low coolant level MON E01
system
Mechanical
B@C6NS Front brake High oil temperature MON E02
system
Mechanical
B@CRNS HST High oil temperature MON E02
system
Electrical
CA111 Engine controller Internal abnormality ENG E03
system
Engine NE, Bkup speed Electrical
CA115 Abnormality ENG E03
sensor system
Electrical
CA122 Charge pressure sensor Abnormally high level ENG E03
system
Electrical
CA123 Charge pressure sensor Abnormally low level ENG E03
system
Electrical
CA131 Throttle sensor Abnormally high level ENG E03
system
Electrical
CA132 Throttle sensor Abnormally low level ENG E03 Troubleshoot-
system
ing by failure
Electrical
CA144 Coolant temperature sensor Abnormally high level ENG E01 code (Display
system
of code), Part 2
Electrical SEN04191-00
CA145 Coolant temperature sensor Abnormally low level ENG E01
system
Electrical
CA153 Charge temperature sensor Abnormally high level ENG E01
system
Electrical
CA154 Charge temperature sensor Abnormally low level ENG E01
system
Abnormally high speed Electrical
CA155 Charge temperature ENG E03
derate system
Electrical
system
Electrical
CA221 Ambient pressure sensor Abnormally high level ENG E01
system
40-100 2 WA320, 320PZ-6

Failure codes table SEN04188-01

Electrical
CA222 Ambient pressure sensor Abnormally low level ENG E01
system
Electrical
system
Mechanical
CA234 Engine Overspeed ENG E02
system
Ne speed sensor power Electrical
CA238 Abnormality ENG E03
supply system
Electrical
CA271 IMV (IMA) Short circuit ENG E03
system
Electrical
CA272 IMV (IMA) Disconnection ENG E03
system
Disconnection/Short cir- Electrical
CA322 Injector #1 system ENG E03
cuit system
Troubleshoot-
Disconnection/Short cir- Electrical ing by failure
cuit system code (Display
Disconnection/Short cir- Electrical of code), Part 2
cuit system SEN04191-00
cuit system
cuit system
cuit system
Electrical
CA342 Engine controller Data mismatching ENG E03
system
Electrical
CA351 Injector drive circuit Abnormality ENG E03
system
Electrical
system
Electrical
system
Electrical
CA428 Water sensor Abnormally high level ENG E01
system
Electrical
CA429 Water sensor Abnormally low level ENG E01
system
Electrical
CA431 Idle validation switch Abnormality ENG E01
system
Electrical
CA432 Idle validation switch Abnormal remedy ENG E03 Troubleshoot-
system
ing by failure
Electrical
CA435 Engine oil pressure switch Abnormality ENG E01 code (Display
system
of code), Part 3
CA441 Power supply voltage Abnormally low level ENG E03
system
Electrical
CA442 Power supply voltage Abnormally high level ENG E03
system
Abnormally high pressure Electrical
CA449 Common rail pressure ENG E03
2 system
Common rail pressure sen- Electrical
CA451 Abnormally high level ENG E03
sor system
WA320, 320PZ-6 40-100 3


Common rail pressure sen- Electrical
CA452 Abnormally low level ENG E03
sor system
Abnormally high torque Electrical

CA488 Charge temperature ENG E03
derate system
Abnormally high pressure Electrical
CA553 Common rail pressure ENG E03
1 system
Electrical
system
Electrical
CA689 Engine Ne speed sensor Abnormality ENG E03
system
Electrical
CA731 Engine Bkup speed sensor Abnormal phase ENG E03
system
Electrical
CA757 Engine controller Loss of all data ENG E03 Troubleshoot-
system
ing by failure
Electrical code (Display
CA778 Engine Bkup speed sensor Abnormality ENG E03
system of code), Part 3
CA1633 KOMNET Abnormality ENG E03
system
Electrical
CA2185 Throttle sensor power supply Abnormally high level ENG E03
system
Electrical
CA2186 Throttle sensor power supply Abnormally low level ENG E03
system
Electrical
system
Electrical
CA2311 IMV (IMA) solenoid Abnormality ENG E03
system
Electrical
CA2555 Intake air heater relay Disconnection ENG E01
system
Electrical
CA2556 Intake air heater relay Short circuit ENG E01
system
Electrical
D160KY Backup lamp/buzzer relay Hot short MON E01
system
Electrical
D192KY ECSS solenoid relay Hot short MON E01
system
Electrical
D1B0KA HST safety relay Disconnection HST E03
system
Electrical
D1B0KB HST safety relay Ground fault HST E01
system
Electrical Troubleshoot-
D1B0KY HST safety relay Hot short HST E03 ing by failure
system
code (Display
Ground fault/Disconnec- Electrical of code), Part 4
D5ZHL6 IGN C system MON E01
tion system SEN04193-01
Ground fault/Disconnec- Electrical
DAF3KK UNSW power supply MON E01
tion system
Monitor panel CAN-NET Electrical
DAFRKR Disconnection HST E03
signal system
HST controller power sup- Electrical
DAJ0KK Low voltage HST E03
ply system
HST controller memory Electrical
DAJ0KT Abnormality HST E01
(EEPROM) system
40-100 4 WA320, 320PZ-6


HST controller main power Disconnection/Ground Electrical
DAJ1L4 HST E01
line fault system
HST controller main power Electrical

DAJ1L6 Hot short HST E01
line system
Controller solenoid power Electrical
DAJ2KK Low voltage HST E03
supply system
HST controller load power Electrical
DAJ2L3 Hot short HST E01 Troubleshoot-
supply holding line system
ing by failure
HST controller load power Disconnection/Ground Electrical code (Display
DAJ2L4 HST E01
supply holding line fault system of code), Part 4
DAJ5KX Sensor 5V power supply Out of input range HST E03
system
Disagreement in model
(DAJ9KQ) HST controller MON E03
selection
Disconnection in signal Electrical
DAJRKR HST controller CAN-NET MON E03
line system
Disagreement in option
(DAJRMA) HST controller MON E03
selection
Disconnection in signal Electrical
DB2RKR Engine controller CAN-NET HST E03
line system
Fan auto reverse switch sig- Electrical
DD1NL4 Abnormality HST E01
nal system
Electrical
DD1NLD Fan reverse switch signal Abnormality HST E01
system
Parking brake reminder Electrical
DDB6KA Disconnection/Hot short HST E01
signal system
Parking brake indicator Electrical
DDB6KB Ground fault HST E01
signal system
Parking brake indicator
Electrical
DDB6KZ signal or parking brake Trouble MON E03
system
reminder signal
Troubleshoot-
Parking brake reminder Electrical ing by failure
DDB6L0 Ground fault HST E01
signal system code (Display
Parking brake indicator Electrical of code), Part 5
DDB6L4 Disconnection/Hot short HST E03 SEN04194-01
signal system
Disconnection/Ground Electrical
DDD7KX Travel speed control dial HST E01
fault system
Electrical
DDD7KY Travel speed control dial Hot short HST E01
system
Emergency steering opera- Electrical
DDE5MA Disconnection MON E01
tion switch system
DDK6KA FNR lever HST E03
fault system
Electrical
DDK6KY FNR lever Hot short HST E03
system
Low oil pressure (Opera- Mechanical
DDS5L6 Steering MON E03
tion of emergency steering) system
WA320, 320PZ-6 40-100 5


Travel speed range selec- Disconnection/Ground Electrical
DF10KA HST E01
tor switch fault system
Travel speed range selec- Electrical
DF10KB Hot short HST E01
tor switch system
Electrical
DGH1KX HST oil temperature sensor Ground fault MON E01
system
Brake oil temperature sen- Electrical
DGR2KB Ground fault MON E01
sor system
Brake oil temperature sen- Electrical
DGR2KZ Disconnection/Hot short MON E01
sor system
DHH1KX HST oil pressure sensor HST E03
fault system
Electrical
DHH1KY HST oil pressure sensor Hot short HST E03
system
Electrical
DHTCL6 HST filter clogging sensor Functional defect MON E01 Troubleshoot-
system
ing by failure
Electrical
DJF1KA Fuel level sensor Disconnection/Hot short MON E01 code (Display
system
of code), Part 6
DLT3KX Travel speed sensor B Abnormality HST E03
system
Electrical
DLT4KX Travel speed sensor A Abnormality HST E03
system
Electrical
DLT4LC Travel speed sensor A & B Abnormality HST E03
system
Electrical
DV00KY Alarm buzzer Hot short MON E01
system
DW26KA Motor 2 solenoid HST E01
fault system
Electrical
DW26KY Motor 2 solenoid Hot short HST E01
system
Electrical
DW7BKY Fan reverse solenoid circuit Hot short HST E01
system
DW7BKZ Fan reverse solenoid circuit HST E01
fault system
Electrical
DX16KA Fan EPC solenoid Disconnection HST E01
system
Electrical
DX16KB Fan EPC solenoid Ground fault HST E01
system
Electrical
DX16KY Fan EPC solenoid Hot short HST E01
system
Electrical
DX19KA Motor 1 solenoid Disconnection HST E03 Troubleshoot-
system
ing by failure
Electrical
DX19KB Motor 1 solenoid Ground fault HST E03 code (Display
system
of code), Part 7
DX19KY Motor 1 solenoid Hot short HST E03
system
Electrical
DX20KA Clutch EPC solenoid Disconnection HST E03
system
Electrical
DX20KB Clutch EPC solenoid Ground fault HST E03
system
Electrical
DX20KY Clutch EPC solenoid Hot short HST E03
system
40-100 6 WA320, 320PZ-6


Electrical
DXH7KB Reverse solenoid Ground fault HST E03
system
Electrical
DXH7KZ Reverse solenoid Disconnection/Hot short HST E03
system
Electrical
DXH8KB Forward solenoid Ground fault HST E03 Troubleshoot-
system
ing by failure
Electrical
DXH8KZ Forward solenoid Disconnection/Hot short HST E03 code (Display
system
of code), Part 7
Mechanical SEN04196-00
J141N1 Steering pump Overrun alarm HST E02
system
Mechanical
M100N1 HST pump Overrun alarm HST E02
system
Mechanical
M400N1 Motor 1 Overrun alarm HST E02
system
a Failure codes:
The failure code table is written in alphabetical order and also starting from small number.
The failure code in parentheses is not recorded in the failure history for both electrical system and
mechanical system.
a Applicable controller:
Applicable controller indicates in which controller system the failure has occurred.
MON : machine monitor system
ENG : Engine controller system
HST : HST controller system
a Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
a History classification:
History classification indicates in which system, either electrical system or mechanical system in the fail-
ure history display function, a failure has been recorded.
a Note: Optional equipments are also included in the table.
WA320, 320PZ-6 40-100 7

SEN04188-01 Fuse locations
Fuse locations 1
Connection table of fuse box and slow blow fuse

a This connection table indicates the devices to which the power of the fuse box and slow blow fuse is
supplied. (A switch power supply is a device which supplies power while the starting switch is in the ON
position and a constant power supply is a device which supplies power while the starting switch is in the
OFF and ON positions).
a When carrying out troubleshooting related to the electrical system, you should check the fuse box and
slow blow fuse to see if the power is supplied normally.
Fuse box: FS1

Type of power supply (Power source) Fuse No. Fuse capacity Destination of power (*)
1 20A Starting switch B
2 10 A Hazard lamp
3 15 A HST controller
4 30 A Engine controller
Unswitched power supply Machine monitor
(Slow blow fuse [50 A]) 5 10 A Tachograph
Buzzer
Radio
6 10 A Auto-grease
Room lamp
7 10 A Unswitched power supply for optional devices
8 10 A Headlamp (left)
9 10 A Headlamp (right)
10 10 A Turn signal lamp
Stop lamp relay
11 10 A Stop lamp switch
Stop lamp
VIS power supply holding relay
12 15 A
HST controller
Detent active relay
Accessory power supply ECSS switch
(Slow blow fuse [80 A]) Quick coupler
13 10 A Boom kick-out relay
PPC solenoid
Bucket leveler relay
Proximity switch
Front/Rear wiper
14 20 A Wiper timer
Window washer
Radio
15 10 A Auto-grease
Cigarette lighter
*: Optional devices are included.

Devices which are not set may be included.
40-100 8 WA320, 320PZ-6

Fuse locations SEN04188-01
Fuse box: FS2

Type of power supply (Power source) Fuse No. Fuse capacity Destination of power (*)
1 20 A Air conditioner blower
2 5A Air conditioner compressor
Beacon
3 20 A Working lamp (Front: For addition)
Rotary lamp
4 20 A Glass heater
5 10 A Load meter, air cleaner clogging relay
Accessory power supply 6 20 A Key ON power for optional device

(Slow blow fuse [80A]) 7 10 A DC converter
8 10 A Parking brake
Horn
9 10 A
Air suspension seat
10 10 A Small lamp (right)
11 10 A Small lamp (left)
12 10 A Working lamp (front)
13 10 A Working lamp (rear)
Machine monitor (Starting switch ACC signal)
14 10 A Backup lamp
ACC signal (ACC switch) Backup alarm
15 5A Engine controller (Starting switch ACC signal)
*: Optional devices are included.

Devices which are not set may be included.
Location Fuse No.

q Inside of cover (1) at rear of console in cab
WA320, 320PZ-6 40-100 9

SEN04188-01 Fuse locations
Slow blow fuse

Type of power supply (Power source) Fuse capacity Destination of power
Fuse box FS1 No.8 15
80 A
Accessory power supply (Battery) Fuse box FS2 No.1 15
120A Engine intake air heater relay
Unswitched power supply (Battery) 50 A Fuse box FS1 No.1 7
Location Arrangement of slow blow fuse

Remove plate (2) on left side of engine compart-
ment and remove cover (3).
40-100 10 WA320, 320PZ-6

Fuse locations SEN04188-01
WA320, 320PZ-6 40-100 11

SEN04188-01

2009 KOMATSU
All Rights Reserved
40-100 12
SEN04189-02
WA320, WA320PZ-6
SEN04189-02
WHEEL LOADER
Shop Manual
WA320-6
WA320PZ-6

WA320-6 70001 and up
40 Troubleshooting
200 General information on troubleshoot-
ing
Points to remember when troubleshooting ................................................................................................. 2

Sequence of events in troubleshooting....................................................................................................... 3
Testing before troubleshooting ................................................................................................................... 4
Classification and procedures of troubleshooting ....................................................................................... 5
Information contained in troubleshooting table ........................................................................................... 8
Connection table for connector pin numbers .............................................................................................. 10
T- branch box and T- branch adapter table ................................................................................................ 46
WA320, WA320PZ-6 40-200 1

200 General information on troubleshooting
SEN04189-02 Points to remember when troubleshooting
Points to remember when troubleshooting
k Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are se-
curely fitted.
k When carrying out the operation with 2 or more workers, keep strictly to the agreed signals, and
do not allow any unauthorized person to come near.
k If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns,
so wait for the engine to cool down before starting troubleshooting.
k Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
k When disconnecting wiring, always disconnect the negative () terminal of the battery first.
k When removing the plug or cap from a location which is under pressure from oil, water, or air, al-
ways release the internal pressure first. When installing measuring equipment, be sure to connect
it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to pre-
vent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to under-
stand the structure and function. However, a shortcut to effective troubleshooting is to ask the operator
various questions to form some idea of possible causes of the failure that would produce the reported symp-
toms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.

If components are disassembled immediately after any failure occurs:
q Parts that have no connection with the failure or other unnecessary parts will be disassembled.
q It will become impossible to find the cause of the failure.
It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confi-
dence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry
out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure.
2. Points to ask the user or operator
1) Have any other problems occurred apart from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the failure? When were these repairs carried out?
6) Has the same kind of failure occurred before?
3. Check before troubleshooting
1) Are abnormal symptoms detected in the machine?
2) Make checks before starting day's work.
3) Make checks of other items.
4) Check other maintenance items which can be visually checked and are considered necessary.
4. Confirming failure
Confirm the extent of the failure by yourself, and judge whether to treat it as a real failure or as a
problem of handling, operation, etc.
a When operating the machine to reenact the troubleshooting symptoms, do not carry out any investiga-
tion or measurement that may make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in items 2 4 to narrow down the causes of
failure, then use the troubleshooting table or flowchart (matrix) to find out the failure part exactly.
a The basic procedure for troubleshooting is as follows.
1] Start from the simple points.
2] Start from the most likely points.
3] Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the immediate failure is repaired, the same failure may occur again, unless the root cause
of the failure is repaired. To prevent this, always investigate why the cause of the failure occurred.
Then, remove the root cause.
40-200 2 WA320, WA320PZ-6

Sequence of events in troubleshooting SEN04189-02
Sequence of events in troubleshooting
WA320, WA320PZ-6 40-200 3

SEN04189-02 Testing before troubleshooting
Testing before troubleshooting

Item Criteria Remedy
1. Check of level and type of fuel Add fuel

2. Check for foreign matter in fuel
Clean or drain
Check fuel filter and fuel pre-filter for clogging
3. Check of fuel filter for clogging Replace
Between H and
4. Check of level and type of oil in engine oil pan Add oil
Lubricating oil and coolant
L
Between FULL
5. Check of coolant level Add coolant
and LOW
6. Check of air cleaner for clogging No red Clean or replace
Between H and
7. Check of level and type of hydraulic oil Add oil
L
Between H and
8. Check of level and type of HST oil Add oil
L
9. Check of engine oil filter for clogging Replace
10. Check of hydraulic oil filter for clogging Replace
11. Check of HST oil filter for clogging Replace
12. Check of battery terminal cables for looseness and corrosion Retighten or replace
Electrical parts
13. Check of alternator terminal cables for looseness and corrosion Retighten or replace
14. Check of starting motor terminal cables for looseness and corrosion Retighten or replace
15. Check of operation of instruments Repair or replace
16. Check for abnormal noise and smell Repair

mechanical equip-
Hydraulic and
17. Check for oil leakage Repair

ment
18. Bleeding air Bleed air
19. Check of effect of brake Repair or adjust
20. Check of battery voltage (with engine stopped) 20 30 V Charge or replace

Between U.L
21. Check of battery electrolyte level Add or replace
and L.L
22. Check wires for discoloration, burn, and removal of cover Replace
Electrical equipment
23. Check for removed wire clamp and drooping wire Repair
24. Check wiring for wetting with water (Check connectors and terminals Disconnect and dry

for wetting with water, in particular) connectors
25. Check of slow-blow fuses and fuses for disconnection and corrosion Replace
After sev-
eral-minute
26. Check of alternator voltage (with engine at medium speed or higher) Repair or replace
operation: 27.5
29.5 V
27. Check of operating sound of battery relay (Starting switch OFF o
Replace
ON)
40-200 4 WA320, WA320PZ-6

Classification and procedures of troubleshooting SEN04189-02
Classification and procedures of troubleshooting

Classification of troubleshooting
Mode Contents
Display of
Troubleshooting by failure code (Display of code)
code
E-mode Troubleshooting of electrical system
H-mode Troubleshooting of hydraulic and mechanical system
S-mode Troubleshooting of engine
Procedure for troubleshooting

If a phenomenon looking like a trouble occurs in the machine, select a proper troubleshooting No. according
to the following procedure, and then go to the corresponding troubleshooting section.
1. Procedure for troubleshooting to be taken when action code is displayed on machine monitor:
If an action code is displayed on the machine monitor, display the failure code in the failure code display
mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
Carry out troubleshooting in [Display of failure code] according to the displayed failure code.
a Each failure code flashes when the trouble corresponding to it is detected. Even if a failure code
lights up when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trouble-
shooting in [Display of code]).
2. Procedure for troubleshooting to be taken when failure code is recorded:

If an action code is not displayed on the machine monitor, check for a failure code in the failure code
display mode (for the electrical system and the mechanical system) of the machine monitor (EMMS).
If a failure code is recorded, carry out troubleshooting in [Display of code] according to that failure code.
a Each failure code flashes when the trouble corresponding to it is detected. Even if a failure code
lights up when the starting switch is turned ON, the trouble corresponding to that failure code may
not have been repaired (Some troubles can be detected by simply turning the starting switch ON).
a If a failure code is recorded, be sure to perform the operation for reproducing it to see if the trouble
corresponding to it has been repaired (For the method of reproducing the failure code, see the trouble-
shooting in [Display of code]).
3. Procedure of troubleshooting to be taken when action code is not displayed and failure code is not
recorded:
If a failure code is not recorded in the machine monitor (EMMS), a trouble that the machine cannot find
out by itself may have occurred in the electrical system or hydraulic and mechanical system.
In this case, check the phenomenon looking like a trouble again and select the same phenomenon from
the table of Phenomena looking like troubles and troubleshooting Nos., and then carry out trouble-
shooting related to that phenomenon in the E-mode, H-mode, or S-mode.
WA320, WA320PZ-6 40-200 5

SEN04189-02 Classification and procedures of troubleshooting
Phenomena looking like troubles and troubleshooting Nos.
Troubleshooting
No. Phenomena looking like trouble Code dis-
E-mode H-mode S-mode
play
Phenomena related to action codes and failure codes
1 Action codes are displayed on machine monitor Check failure code
2 If failure code display function is checked, failure codes are displayed q
Phenomena related to engine
3 Engine does not start easily (Starting performance is poor) S-1
4 Engine does not turn E-1 S-2 a)
Engine turns but no exhaust smoke comes
5 Engine does not start S-2 b)
out
Exhaust smoke comes out but engine
6 S-2 c)
does not start (Fuel is injected)
7 Engine does not pick up smoothly S-3
8 Engine stops during operation H-4 S-4
9 Engine does not rotate smoothly S-5
10 Engine lacks output (or lacks power) S-6
11 Exhaust smoke is black (Incomplete combustion) S-7
12 Oil consumption is excessive (or exhaust smoke is blue) S-8
13 Oil becomes contaminated quickly S-9
14 Fuel consumption is excessive S-10
15 Oil is in coolant (or coolant spurts back or coolant level goes down) S-11
16 Oil pressure drops S-12
17 Oil level rises (Entry of coolant or fuel) S-13
18 Coolant temperature becomes too high (overheating) S-14
19 Abnormal noise is made S-15
20 Vibration is excessive S-16
21 Preheater does not operate normally E-2
Phenomena related to power train
22 The machine does not start H-1
23 The travel speed is low E-3 a), b) H-2
24 The travel speed is high E-3 c)
25 The traction force is weak H-3
26 Engine stalls when traveling or engine speed drops excessively H-4
27 Shift range is not shifted H-5
28 Travel direction selection system does not function E-9
Phenomena related to steering
29 The steering wheel does not turn H-6
30 The steering wheel is heavy H-7
31 Steering wheel shakes or jerks H-8
32 Machine deviates naturally to one side when traveling H-9
Phenomena related to brake
33 The brake does not work or does not work well H-10
34 The brake is not released or is dragged H-11
40-200 6 WA320, WA320PZ-6

Classification and procedures of troubleshooting SEN04189-02
Phenomena related to work equipment

35 The lift arm does not rise or lower H-12
36 The lift arm moves slowly or the lift arm rising force is insufficient H-13
37 When rising, the lift arm comes to move slowly at specific height H-14
The lift arm cylinder cannot hold down the bucket (The bucket rises in
38 H-15
the air)
39 Hydraulic drifts of the lift arm occur often H-16
40 The lift arm wobbles during operation H-17
When the control lever is switched from "HOLD" to "RAISE," the lift
41 H-18
arm falls temporarily
42 The bucket does not tilt back H-19
43 The bucket moves slowly or the tilting-back force is insufficient H-20
44 The bucket comes to operate slowly in the midst of tilting-back H-21
45 The bucket cylinder cannot hold down the bucket H-22
46 Hydraulic drifts of the bucket occur often H-23
The bucket wobbles during travel with load (The work equipment
47 H-24
valve is set to "HOLD")
When the control lever is switched from "HOLD" to "TILT," the bucket
48 H-25
falls temporarily
The control levers of the lift arm and bucket do not move smoothly
49 H-26
and heavy
50 The ECSS does not operate and machine pitches and bounces E-4 H-27
51 ECCS keeps operating E-5
52 Defective boom kick-out function and cancellation E-6
53 Defective bucket positioner function and cancellation E-7
54 Defective lift arm FLOATING holding function and cancellation E-8
Others
Fan revolution is abnormal (Fan sound/vibration is abnormally large
55 H-28
or engine overheats)
56 Fan does not reverse E-10
57 Fan keeps rotating in reverse E-11
58 Wiper does not operate E-12
59 Windshield washer does not operate E-13
60 Headlamp, clearance lamp and tail lamp do not light up or go off E-14
61 Working lamp does not light up or go off E-15
62 Turn signal lamp and hazard lamp do not light up or go off E-16
63 Brake lamp does not light or it keeps lighting up E-17
64 Backup lamp does not light or it keeps lighting up E-18
65 Backup alarm does not sound or it keeps sounding E-19
66 Horn does not sound or it keeps sounding E-20
67 Alarm buzzer does not sound or it keeps sounding E-21
68 Air conditioner does not operate or stop E-22
69 The KOMTRAX system does not work properly E-23
WA320, WA320PZ-6 40-200 7

SEN04189-02 Information contained in troubleshooting table
Information contained in troubleshooting table
Action code Failure code

Monitor dis- Trouble Problem that appears on machine
Monitor display
play
Contents of
State where the monitor panel or controller detects the trouble
trouble
Action of con- Action taken by machine monitor or controller to protect system or devices when engine con-
troller troller detects trouble
Problem that
Problem that appears on machine as result of action taken by machine monitor or controller
appears on
(shown above)
machine
Related infor-
Information related to detected trouble or troubleshooting
mation
Cause Standard value in normal state/Remarks on troubleshooting
<Described contents>
q Standard value in normal state to judge assumed cause
(good or not)
q Remarks required to judge whether the cause is good
1
<Phenomenon of defective wiring harness>

q Disconnection in wiring
The connector connection is defective or the wiring
harness is disconnected.
q Grounding fault
A harness not connected to ground (earth) circuit comes
into contact with the ground (earth) circuit.
q Hot short circuit
A harness not connected to the power (24 V) circuit comes
2 into contact with the power (24 V) circuit.
q Short circuit
A harnesses of an independent circuit abnormally comes
Possible causes Possible causes of trouble into contact with one of another circuit.
and standard is assumed to be detected
value in normal (The order number indicates
state a serial number, not a priority
sequence.) <Notes on troubleshooting>
(1) Method of indicating connector number and handling
T-branch
3 For troubleshooting, insert or connect T-branch adapter as
shown below unless especially specified.
q When male or female is not indicated for a connec-
tor number, disconnect the connector, and insert the
T-branch adapter in both the male and female.
q When male and female is indicated for a connector
number, disconnect the connector, and insert the
T-branch adapter in only either the male or female.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the plus (+) and minus ()
4 leads as shown below unless especially specified.
q Connect the plus (+) lead to a pin or harness indicated
in the front.
q Connect the minus () lead to a pin or harness indicated
in the rear.
40-200 8 WA320, WA320PZ-6

Information contained in troubleshooting table SEN04189-02
Related circuit diagram
This is the excerpted circuit diagram related to trouble

q Connector No.: Indicates (Model No. of pins) (Color)
q Connector No. and pin No. from each branching/
merging point: Shows the ends of branch or source
of merging within the parts of the same wiring har-
ness.
q Arrow (io): Roughly shows the location on the ma-
chine.
WA320, WA320PZ-6 40-200 9

SEN04189-02 Connection table for connector pin numbers
Connection table for connector pin numbers

(Rev. 2009. 06)
a The terms of male and female refer to the pins, while the terms of male housing and female housing refer
to the mating portion of the housing.
40-200 10 WA320, WA320PZ-6

Connection table for connector pin numbers SEN04189-02
WA320, WA320PZ-6 40-200 11

40-200 12 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 13

40-200 14 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 15

40-200 16 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 17

40-200 18 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 19

40-200 20 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 21

40-200 22 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 23

40-200 24 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 25

40-200 26 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 27

40-200 28 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 29

40-200 30 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 31

40-200 32 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 33

40-200 34 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 35

40-200 36 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 37

40-200 38 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 39

40-200 40 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 41

40-200 42 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 43

40-200 44 WA320, WA320PZ-6

WA320, WA320PZ-6 40-200 45

SEN04189-02 T- branch box and T- branch adapter table
T- branch box and T- branch adapter table

(Rev. 2009. 03)
a The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal col-
umn indicates a part number of harness checker assembly.
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-2600 T-box (for ECONO) 21 q q q q q

799-601-3100 T-box (for MS) 37 q
799-601-3200 T-box (for MS) 37 q
799-601-3380 Plate for MS (14-pin) q
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P q
799-601-3470 Case q
799-601-2710 Adapter for MIC 5 MIC-5P q q q
799-601-2720 Adapter for MIC 13 MIC-13P q q q
799-601-2730 Adapter for MIC 17 MIC-17P q q q q q q
799-601-2740 Adapter for MIC 21 MIC-21P q q q q q q
799-601-2950 Adapter for MIC 9 MIC-9P q q q q
799-601-2750 Adapter for ECONO 2 ECONO2P q q
799-601-2810 Adapter for DLI 8 DLI-8P q q
799-601-2840 Extension cable (ECONO type) 12 ECONO12P q q q
799-601-2850 Case q
799-601-4350 T-box (for DRC 60, ECONO) 60 q
799-601-4360 Case q
799-601-7010 Adapter for X (T-adapter) 1 q q
799-601-7020 Adapter for X 2 X2P q q q q
799-601-7050 Adapter for SWP 6 SW6P q q q
799-601-7060 Adapter for SWP 8 SW8P q q q
799-601-7310 Adapter for SWP 12 SW12P q
799-601-7070 Adapter for SWP 14 SW14P q q
799-601-7320 Adapter for SWP 16 SW16P q
799-601-7080 Adapter for M (T-adapter) 1 q q
799-601-7090 Adapter for M 2 M2P q q q q
40-200 46 WA320, WA320PZ-6

T- branch box and T- branch adapter table SEN04189-02
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol

799-601-7340 Adapter for M 8 M8P q
799-601-7140 Adapter for S 8 S8P q q q q
799-601-7150 Adapter for S (White) 10 S10P q q q q
799-601-7160 Adapter for S (Blue) 12 S12P q q q
799-601-7170 Adapter for S (Blue) 16 S16P q q q q
799-601-7330 Adapter for S (White) 16 S16PW q
799-601-7350 Adapter for S (White) 12 S12PW q
799-601-7180 Adapter for AMP040 8 A8P q
799-601-7190 Adapter for AMP040 12 A12P q q
799-601-7210 Adapter for AMP040 16 A16P q q q q
799-601-7220 Adapter for AMP040 20 A20P q q q q
799-601-7230 Short connector for X 2 q q q q
799-601-7240 Case q q
799-601-7270 Case q
799-601-7510 Adapter for 070 10 07-10 q
799-601-7520 Adapter for 070 12 07-12 q
799-601-7530 Adapter for 070 14 07-14 q
799-601-7540 Adapter for 070 18 07-18 q
799-601-7550 Adapter for 070 20 07-20 q
799-601-7360 Adapter for relay 5 REL-5P q
799-601-7370 Adapter for relay 6 REL-6P q
799-601-7380 Adapter for JFC 2 q
799-601-9010 Adapter for DTM 2 DTM2 q q
799-601-9020 Adapter for DT 2 DT2 q q q q
799-601-9030 Adapter for DT 3 DT3 q q
799-601-9040 Adapter for DT 4 DT4 q q q q
799-601-9050 Adapter for DT 6 DT6 q q
799-601-9060 Adapter for DT (Gray) 8 DT8GR q q
799-601-9070 Adapter for DT (Black) 8 DT8B q q
799-601-9080 Adapter for DT (Green) 8 DT8G q q
799-601-9090 Adapter for DT (Brown) 8 DT8BR q q
799-601-9110 Adapter for DT (Gray) 12 DT12GR q q
799-601-9120 Adapter for DT (Black) 12 DT12B q q
799-601-9130 Adapter for DT (Green) 12 DT12G q q
799-601-9140 Adapter for DT (Brown) 12 DT12BR q q
799-601-9210 Adapter for HD30-18 8 D18-8 q q
799-601-9310 Plate for HD30 (24-pin) q q q
799-601-9320 T-box (for ECONO) 24 q q q
799-601-9330 Case q
WA320, WA320PZ-6 40-200 47

SEN04189-02 T- branch box and T- branch adapter table
T-adapter kit
Number of pins
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Out of kit
Identification
Part No. Part name
symbol
799-601-9340 Case q
799-601-9350 Adapter for DRC 40 DRC-40 q
799-601-9360 Adapter for DRC 24 DRC-24 q
799-601-9410* Socket for engine (CRI-T2) 2 G q
Adapter for engine (CRI-T2)
799-601-9420 Adapter for engine (CRI-T3) PFUEL 3 A3 q q
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430*
Socket for engine (CRI-T3) PCV
2 P q q
799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 q
795-799-5520* Socket for engine (HPI-T2) 2 S q
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C q q
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540*
Socket for engine(CRI-T3) TIM
2 A q q
795-799-5460 Cable for engine (HPI-T2) 3 q
799-601-4110 Adapter for engine (140-T3) PIM 4 ITT3N q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM 3 FCIN q q
799-601-4140
Atomosphere pressure
3 FCIG q q
799-601-4150 Adapter for engine (CRI-T3) POIL 3 FCIB q q
799-601-4160
Oil pressure switch
2 4160 q q
799-601-4180 Adapter for engine (CRI-T3) PEVA 3 4180 q q
799-601-4190*
Common rail pressure
3 1, 2, 3L q q

799-601-4230*
Air intake pressure/temperature
4 1, 2, 3, 4C q q
799-601-4240* Socket for engine (CRI-T3) PAMB 3 1, 2, 3A q q
799-601-4250* Socket for engine (CRI-T3) PIM 3 1, 2, 3B q q
799-601-4330* Socket for engine (CRI-T3) G 3 1, 2, 3, G q q
799-601-4340*
Pump actuator
2 2, PA q q
Socket for engine (CRI-T3)(95)

799-601-4380*
Air intake pressure/temperature
4 1, 2, 3, 4T q
799-601-4260 Adapter for controller (ENG) 4 DTP4 q q
799-601-4211 Adapter for controller (ENG) 50 DRC50 q
799-601-4220 Adapter for controller (ENG) 60 DRC60 q
799-601-4390* Socket for controller (95 ENG) 60 q
799-601-4280* Box for controller (PUMP) 121 q
799-601-9720 Adapter for controller (HST) 16 HST16A q
799-601-9710 Adapter for controller (HST) 16 HST16B q
799-601-9730 Adapter for controller (HST) 26 HST26A q
2,
799-601-9890 Multi-adapter for DT2 4 and DTM2 3, q
4
* Shows not T-adapter but socket.
40-200 48 WA320, WA320PZ-6

T- branch box and T- branch adapter table SEN04189-02
WA320, WA320PZ-6 40-200 49

SEN04189-02
2009 KOMATSU
All Rights Reserved
40-200 50
SEN04190-00
WA320-6
WA320PZ-6
WA320-6 70001 and up

310 Troubleshooting by failure code

(Display of code), Part 1
Failure code [2G40ZG] Brake: Oil pressure reduction.................................................................................... 2
Failure code [6091NX] HST filter: Clogging .................................................................................................... 4
Failure code [989FN1] Travel speed: Overrun alarm...................................................................................... 5
Failure code [AA1ANX] Air cleaner: Clogging................................................................................................. 6
Failure code [AB00L6] Alternator R system: Hot short ................................................................................... 8
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage ................... 10
Failure code [B@BAZG] Engine: Oil pressure reduction .............................................................................. 12
Failure code [B@BAZK] Engine oil: Low level .............................................................................................. 13
Failure code [B@BCNS] Engine: Overheat .................................................................................................. 14
Failure code [B@BCZK] Engine: Low coolant level...................................................................................... 16
Failure code [B@C6NS] Front brake: High oil temperature.......................................................................... 18
Failure code [B@CRNS] HST: High oil temperature..................................................................................... 19
WA320, 320PZ-6 40-310 1

310 Troubleshooting by failure code (Display of code), Part 1
SEN04190-00 Failure code [2G40ZG] Brake: Oil pressure reduction
Failure code [2G40ZG] Brake: Oil pressure reduction

Action code Failure code Brake: Oil pressure reduction
Trouble
E03 2G40ZG (Machine monitor system)
Contents of While engine was running (for at least 30 seconds), brake oil pressure sensor detected that oil pres-
trouble sure was below 4.4 MPa {45 kg/cm2} (circuit is open).
Turns central warning lamp and caution buzzer ON.
Turns brake oil pressure caution lamp ON.
Action of
machine monitor Central warning lamp, alarm buzzer and caution lamp operate for a maximum of 30 seconds after the
engine starts, but no failure codes are displayed.
if cause of failure disappears, system resets itself.
Problem that
appears on If machine is used as it is, brake may not work.
machine
Related Input state (ON/OFF) from brake oil pressure sensor can be checked with monitoring function
information (Monitoring code: MONITOR PANEL 40902 D-IN-16).
Causes Standard value in normal state/Remarks on troubleshooting

System is normal.
1 Brake oil pressure reduction
a Carry out troubleshooting for hydraulic and mechanical systems.
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
T12 (male) Oil pressure Resistance
Defective brake oil pressure
2 Min. 5.88 MPa
sensor (Internal defect) Max. 1 z
{60 kg/cm2}
Between (1) (2)
Max. 3.92 MPa
Min. 1 Mz
{40 kg/cm2}
Possible causes
a Prepare with starting switch OFF, then carry out troubleshooting
and standard
Disconnection in wiring har- without turning starting switch ON.
value in normal
state ness (Disconnection in wiring Wiring harness between T12 (female) (1) Resis-
3 Max. 1 z
or defective contact in con- L26 (female) (1) tance
nector) Wiring harness between T12 (female) (2) Resis-
Max. 1 z
ground tance
a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting.
L26 Oil pressure Voltage
4 Defective machine monitor Min. 5.88 MPa
Max. 1 V
{60 kg/cm2}
Between (1) ground
Max. 3.92 MPa
20 30 V
{40 kg/cm2}
40-310 2 WA320, 320PZ-6

Failure code [2G40ZG] Brake: Oil pressure reduction SEN04190-00
WA320, 320PZ-6 40-310 3

SEN04190-00 Failure code [6091NX] HST filter: Clogging
Failure code [6091NX] HST filter: Clogging

Action code Failure code HST filter: Clogging
Trouble
E01 6091NX (Machine monitor system)
Contents of When HST oil temperature was above 50C, HST oil filter clogging sensor signal circuit was closed
trouble (in contact with GND).
Action of Turns HST clogging caution lamp ON.
machine monitor if cause of failure disappears, system resets itself.
Problem that
appears on If machine is used as it is, foreign matter may enter HST circuit.
machine
Related The input state from the HST oil filter clogging sensor can be checked with monitoring function
information (Monitoring code: MONITOR PANEL 40903 D-IN-24)

System is normal.
1 Clogged HST oil filter
a Check HST oil filter directly.
without turning starting switch ON.
Defective HST oil filter clog- T13 Filter condition Resistance
2
ging sensor (Internal defect)
Between T13 Not clogged (Normal) Min. 1 Mz
ground Clogged Max. 1 z
Possible causes
and standard
value in normal
state ness (Disconnection in wiring Wiring harness between T13 L26 (female) Resis-
3 Max. 1 z
or defective contact in con- (5) tance
nector) Wiring harness between HST oil filter clog- Resis-
Max. 1 z
ging sensor body ground tance
4 Defective machine monitor L26 Filter condition Voltage
Not clogged (Normal) 20 30 V
Between (5) ground
Clogged Max. 1 V
40-310 4 WA320, 320PZ-6

Failure code [989FN1] Travel speed: Overrun alarm SEN04190-00
Failure code [989FN1] Travel speed: Overrun alarm

Action code Failure code Travel speed: Overrun alarm
Trouble
E02 989FN1 (Machine monitor system)
Contents of Travel speed exceeded 45 km/h.
trouble Auto-decelerator does not work at speed higher than 40 km/h.
Action of
Turns central warning lamp and caution buzzer ON.
machine monitor
Problem that
appears on If machine is used as it is, brake etc. may be damaged.
machine
Related
If [DW26KA] or [DW26KY] is displayed, carry out troubleshooting for it first.
information

System is normal (when machine is used as it overruns by acceler-
Possible causes ating on sharp downhill road etc.)
1 Overrun
and standard a Check using condition and teach operator correct using method.
value in normal a Check related components for damage.
state If alarm is turned ON while travel speed is below limit, machine
2 Defective machine monitor monitor may be defective. (Since trouble is in system, trouble-
shooting cannot be carried out.)
WA320, 320PZ-6 40-310 5

SEN04190-00 Failure code [AA1ANX] Air cleaner: Clogging
Failure code [AA1ANX] Air cleaner: Clogging 1
Action code Failure code Air cleaner: Clogging

Trouble
E01 AA1ANX (Machine monitor system)
Contents of
When the engine is started, the air cleaner clogging sensor circuit is OPEN.
trouble
Action of Turns the air cleaner clogging caution lamp ON.
controller If problem is removed, system is returned to normal operating state.
Problem that
The engine does not start or pick up easily, its output is insufficient, and its exhaust gas color is
appears on
black.
machine
The input state (ON/OFF) from the air cleaner clogging sensor can be checked with the monitoring
Related
function (Code: MONITOR PANEL, 40902, D-IN-20).
information
Method of reproducing failure code: Start engine

1 Clogged air cleaner The air cleaner may be clogged. Check it directly.
Defective dust indicator troubleshooting.
2
(Internal short circuit) Replace the dust If the condition becomes normal, the trouble
indicator is attributable to defective indicator.
L112 (Male) Resistance
Defective dust indicator relay
Between (1) and (2) 200 400 z
(L112)
3 a Prepare with starting switch OFF, then start engine and carry out
(Internal disconnection or
short circuit) troubleshooting.
When dust indicator relay (L112) is replaced with a relay of the
same type (5-pin type), if the condition becomes normal, the
Possible causes exchange relay is defective.
and standard a Prepare with starting switch OFF, then carry out troubleshooting
value in normal without turning starting switch ON.
Disconnection in wiring har-
state
ness Wiring harnesses between L112 (female) Resis-
4 Max. 1 z
(Disconnection or defective (6) L26 (female) (3) tance
contact in connector) Wiring harnesses between L112 (female) Resis-
Max. 1 z
(3) chassis ground tance
Grounding fault in wiring har- without turning starting switch ON.
5 ness
(Contact with ground circuit) Wiring harness between L112 (female) (6) Resis-
Min. 1 Mz
L26 (female) (3) and chassis ground tance
troubleshooting.
L26 Dust indicator Voltage
6 Defective machine monitor Normal (Air cleaner is
Max. 1 V
Between (3) and normal)
chassis ground Defective (Air cleaner
20 30 V
is clogged)
40-310 6 WA320, 320PZ-6

Failure code [AA1ANX] Air cleaner: Clogging SEN04190-00
Circuit diagram related to dust indicator
WA320, 320PZ-6 40-310 7

SEN04190-00 Failure code [AB00L6] Alternator R system: Hot short
Failure code [AB00L6] Alternator R system: Hot short

Action code Failure code Alternator R system: Hot short
Trouble
E01 AB00L6 (Machine monitor system)
Contents of
When engine is stopped, alternator terminal R input voltage is above 12 V.
trouble
Action of
Turns the charge circuit error caution lamp ON.
machine monitor
Problem that
appears on After the engine is started, just turning on the starting switch runs the service meter.
machine
The input state (voltage) from the alternator can be checked with the monitoring function (Monitoring
Related
code: HST 04302 ALTERNATOR R).
information
Method of reproducing failure code: Turn the starting switch ON.

troubleshooting.
Defective alternator Alternator Engine Voltage
1
(Internal trouble) Wiring harness Running (Throttle:
27.5 29.5 V
between E02 Above 1/2)
(female) (1) ground Holds in position Max. 1.5 V
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal Hot short in wiring harness
2 Wiring harnesses between E02 (female) (1)
state (Contact with 24V circuit)
L25 (female) (18), circuit branch end and Voltage Max. 1 V
ground
troubleshooting.
L25 Engine Voltage
3 Defective machine monitor
Running
Between (18) and 27.5 29.5 V
(Throttle: Above 1/2)
ground
Holds in position Max. 1.5 V
40-310 8 WA320, 320PZ-6

Failure code [AB00L6] Alternator R system: Hot short SEN04190-00
WA320, 320PZ-6 40-310 9

SEN04190-00 Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/

Low charge voltage
Action code Failure code Alternator R system: Ground fault/Disconnection/Low charge volt-
Trouble age
E03 AB00MA (Machine monitor system)
Contents of
While the engine is running, the alternator terminal R input voltage is below 5 V.
trouble
Action of Turns the charge circuit failure caution lamp ON.
machine monitor Turns the centralized warning lamp and alarm buzzer ON.
Problem that
Deterioration of battery or insufficient charging
appears on
machine Engine does not start.
The input state (voltage) from the alternator can be checked with the monitoring function (Monitoring
Related
code: HST 04302 ALTERNATOR R).
information

1 The battery is deteriorated. The battery may be deteriorated. Check it directly.
troubleshooting.
Defective alternator Alternator Engine Voltage
2
(Internal trouble) Wiring harness Running (Throttle:
27.5 29.5 V
between E02 Above 1/2)
(female) (1) ground Holds in position Max. 1.5 V
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness without turning starting switch ON.
Possible causes 3
(Disconnection or defective Wiring harnesses between E02 (female) (1) Resis-
and standard
contact in connector) Max. 1 z
value in normal L25 (female) (18) tance
state a Prepare by turning starting switch OFF and then start engine to
Grounding fault in wiring har- carry out troubleshooting.
4 ness Wiring harness between E02 (female) (1)
(Contact with ground circuit) L25 (female) (18) circuit branch end and Resis-
Min. 1 Mz
tance
ground
troubleshooting.
L25 Engine Voltage
Running (Throttle:
Between (18) and 27.5 29.5 V
Above 1/2)
ground
Holds in position Max. 1.5 V
40-310 10 WA320, 320PZ-6

Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage SEN04190-00
WA320, 320PZ-6 40-310 11

SEN04190-00 Failure code [B@BAZG] Engine: Oil pressure reduction
Failure code [B@BAZG] Engine: Oil pressure reduction

Action code Failure code Engine: Oil pressure reduction
Trouble
E03 B@BAZG (Engine controller system)
Contents of
While engine is run, engine oil pressure became lower than operating range.
trouble
Action of Limits output and continues operation (Limits fuel injection rate and engine speed).
Problem that
appears on Engine output lowers.
machine
Related
information

Low engine oil pressure Engine oil has potentially gone low. Check the pressure and if it is
1
(When the system is normal) below the specified level, locate and eliminate the cause.
Defective engine oil pressure troubleshooting.
2 switch
OIL PRESSURE SWITCH Resistance
(Internal trouble)
Possible causes Between terminals Min. 1 Mz
and standard
value in normal a Prepare with starting switch OFF, then carry out troubleshooting
state Ground fault in wiring harness without turning starting switch ON.
3
(Contact with GND circuit) Wiring harnesses between EC1 (female) Resis-
Min. 1 Mz
(17) OIL PRESSURE SWITCH and ground tance
troubleshooting.
4 Defective engine controller
EC1 Resistance
Between (17) and ground Min. 1 Mz
40-310 12 WA320, 320PZ-6

Failure code [B@BAZK] Engine oil: Low level SEN04190-00
Failure code [B@BAZK] Engine oil: Low level 1
Action code Failure code Engine oil: Low level

Trouble
E01 B@BAZK (Machine monitor system)
While engine is stopped, the engine oil level sensor circuit was detected to have remained in OPEN
condition for more than 2 seconds.
Contents of
(This error, however, is not detected for 5 minutes from the engine stop)
trouble
An error being detected at stopping the engine remains as the error after the engine is started again
until the normal condition is recovered.
Action of Turns the engine oil level caution lamp ON.
Problem that
appears on The engine oil level is low (The engine may be broken).
machine
The input state (ON/OFF) from the engine level sensor can be checked with the monitoring function
Related
(Code: MONITOR PANEL, 40903, D-IN-29).
information

1 Low engine oil level The engine oil level may be low. Check it directly.
Defective engine oil level E26 (male) Engine oil level Resistance
2 sensor
(Internal disconnection) Oil level is normal Max. 1 z
Between (1) and
chassis ground Oil level is insuffi-
Min. 1 Mz
Possible causes cient (low level)
and standard Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
value in normal ness without turning starting switch ON.
state 3
(Disconnection or defective Wiring harnesses between L27 (female) (11) Resis-
contact) Max. 1 z
E26 (female) (1) tance
L27 (female) Engine oil level Voltage
Wiring harness Oil level is normal 20 30 V
between (11) chas- Oil level is insuffi-
sis ground Max. 1 V
cient (low level)
WA320, 320PZ-6 40-310 13

SEN04190-00 Failure code [B@BCNS] Engine: Overheat
Failure code [B@BCNS] Engine: Overheat

Action code Failure code Engine: Overheat
Trouble
E02 B@BCNS (Engine controller system)
Contents of While engine was running, engine coolant temperature sensor signal circuit detected engine coolant
trouble overheat.
Action of Limits fuel injection until coolant temperature lowers to operating range.
machine monitor Turns central warning lamp and caution buzzer ON.
Problem that
appears on Engine output decreases.
machine
Related Engine coolant temperature can be checked with monitoring function.
information (Monitoring code: ENGINE 04104 COOLANT TEMP (C))

Engine coolant overheat
1 Engine coolant may be overheating. Remove cause of overheat.
(when system is normal)
Possible causes
and standard If cause 1 is not detected, engine coolant temperature sensor sys-
Defective engine coolant
value in normal 2 tem may be defective. Carry out troubleshooting for failure codes
temperature sensor system
state [CA144] and [CA145].
If causes 1 and 2 are not detected, engine controller may be defec-
3 Defective engine controller tive. Carry out troubleshooting for failure codes [CA144] and
[CA145].
40-310 14 WA320, 320PZ-6

Failure code [B@BCNS] Engine: Overheat SEN04190-00
WA320, 320PZ-6 40-310 15

SEN04190-00 Failure code [B@BCZK] Engine: Low coolant level
Failure code [B@BCZK] Engine: Low coolant level

Action code Failure code Engine: Low coolant level
Trouble
E01 B@BCZK (Machine monitor system)
Contents of
Radiator coolant level switch signal circuit was opened (disconnected from GND) for 30 seconds.
trouble
Action of
Turns radiator coolant level caution lamp ON.
machine monitor
Problem that
appears on If machine is used as it is, engine may overheat.
machine
Related Operation of radiator coolant level switch can be checked with monitoring function.

System is normal.
Low radiator sub-tank cool-
1 a Radiator sub-tank coolant level may be low. Check and add cool-
ant level
ant, if necessary.
Sub-tank coolant
Defective radiator coolant B05 (male) Resistance
2 level
level switch (Internal defect)
Above low level
Max. 1 z
Between (1) (2) (Normal)
Possible causes Below low level Min. 1 Mz

value in normal Disconnection in wiring har- without turning starting switch ON.
state ness (Disconnection in wiring Wiring harness between L27 (female) (10) Resis-
3 Max. 1 z
or defective contact in con- B05 (female) (1) tance
nector) Wiring harness between B05 (female) (2) Resis-
Max. 1 z
ground tance
Sub-tank coolant
L27 Voltage
4 Defective machine monitor level
Above low level
Between (10) Max. 1 V
(Normal)
ground
Below low level 20 30 V
40-310 16 WA320, 320PZ-6

Failure code [B@BCZK] Engine: Low coolant level SEN04190-00
WA320, 320PZ-6 40-310 17

SEN04190-00 Failure code [B@C6NS] Front brake: High oil temperature
Failure code [B@C6NS] Front brake: High oil temperature

Action code Failure code Front brake: High oil temperature
Trouble
E02 B@C6NS (Machine monitor system)
Front brake (axle) high oil temperature was detected (Details are as follows).
Contents of
trouble Oil temperature above 130C (when travel speed was below 35 km/h) or above 125C (when travel
speed was above 35 km/h) was detected for 5 seconds continuously.
Action of Turns central warning lamp and caution buzzer ON.
machine monitor Turns brake oil temperature caution lamp ON.
Problem that
appears on If machine is used as it is, brake may be damaged.
machine
If temperature above 120C is detected for 5 seconds continuously, only caution lamp is turned ON
as preliminary warning.
Related
information Brake oil temperature can be checked with monitoring function.
(Monitoring code: MONITOR PANEL 30201 F BRAKE OIL (C))
(Monitoring code: MONITOR PANEL 30204 F BRAKE OIL (V))

System is normal.
Front brake (Axle) high oil
1 a Front brake (Axle) oil may be overheated. Remove cause of over-
temperature
Possible causes heat.
and standard If cause 1 is not detected, brake oil temperature sensor system may
value in normal Defective brake oil tempera-
2 be defective. Carry out troubleshooting for failure codes [DGR2KB]
state ture sensor
and [DGR2KZ].
If causes 1 and 2 are not detected, machine monitor may be defec-
3 Defective machine monitor tive. Carry out troubleshooting for failure codes [DGR2KB] and
[DGR2KZ].
40-310 18 WA320, 320PZ-6

Failure code [B@CRNS] HST: High oil temperature SEN04190-00
Failure code [B@CRNS] HST: High oil temperature

Action code Failure code HST: High oil temperature
Trouble
E02 B@CRNS (Machine monitor system)
Contents of
HST oil temperature higher than 105C was detected for 10 seconds continuously.
trouble
Action of Turns central warning lamp and caution buzzer ON.
machine monitor Turns HST oil temperature caution lamp ON.
Problem that
appears on If machine is used as it is, hydraulic system equipments may be damaged.
machine
HST oil temperature can be checked with monitoring function.
Related
(Monitoring code: MONITO PANEL 04408 HST OIL TEMP (C))
information
(Monitoring code: MONITO PANEL 04409 HST OIL TEMP (V))

System is normal.
Possible causes 1 HST high oil temperature
a HST oil may be overheated. Remove cause of overheat.
and standard
value in normal Defective HST oil tempera- If cause 1 is not detected, HST oil temperature sensor system may
2
state ture sensor be defective. Carry out troubleshooting for failure code [DGH1KX].
tive. Carry out troubleshooting for failure code [DGH1KX].
WA320, 320PZ-6 40-310 19

SEN04190-00

2008 KOMATSU
All Rights Reserved
40-310 20
SEN04191-00
WA320-6
WA320PZ-6
WA320-6 70001 and up


Failure code [CA111] Abnormality in engine controller ................................................................................... 3
Failure code [CA115] Engine Ne or Bkup speed sensor error ........................................................................ 4
Failure code [CA122] Charge pressure sensor high error .............................................................................. 6
Failure code [CA123] Charge pressure sensor low error................................................................................ 8
Failure code [CA131] Throttle sensor high error........................................................................................... 10
Failure code [CA132] Throttle sensor low error ............................................................................................ 12
Failure code [CA144] Coolant sensor high error........................................................................................... 14
Failure code [CA145] Coolant sensor low error ............................................................................................ 16
Failure code [CA153] Charge temperature sensor high error....................................................................... 18
Failure code [CA154] Charge temperature sensor low error ........................................................................ 20
Failure code [CA155] Derating of speed by abnormally high charge temperature ....................................... 22
Failure code [CA221] Atmospheric pressure sensor high error .................................................................... 26
Failure code [CA222] Atmospheric sensor low error .................................................................................... 28
Failure code [CA234] Engine overspeed ...................................................................................................... 31
Failure code [CA238] Ne speed sensor power supply error ......................................................................... 32
Failure code [CA271] IMV (IMA) Short circuit ............................................................................................... 33
Failure code [CA272] IMV (IMA) Disconnection ........................................................................................... 34
Failure code [CA322] Injector #1 open/short error........................................................................................ 36
Failure code [CA323] Injector #5 open/short error........................................................................................ 38
WA320, 320PZ-6 40-320 1

SEN04191-00

Failure code [CA342] Calibration code inconsistency................................................................................... 48
Failure code [CA351] Injectors drive circuit error .......................................................................................... 50
40-320 2 WA320, 320PZ-6

Failure code [CA111] Abnormality in engine controller SEN04191-00
Failure code [CA111] Abnormality in engine controller 1
Action code Failure code Abnormality in engine controller

Trouble
E03 CA111 (Engine controller system)
Contents of
Abnormality occurred in memory of engine controller or power supply circuit.
trouble
Action of
Turns the centralized warning lamp and alarm buzzer ON.
controller
Problem that
appears on The engine does not start.
machine
Related
information
Possible causes Causes Standard value in normal state/Remarks on troubleshooting

and standard
value in normal Possible defect in engine controller (Troubleshooting cannot be car-
state ried out.)
WA320, 320PZ-6 40-320 3

SEN04191-00 Failure code [CA115] Engine Ne or Bkup speed sensor error
Failure code [CA115] Engine Ne or Bkup speed sensor error 1
Action code Failure code Engine Ne or Bkup speed sensor error

Trouble
Contents of
Abnormality occurred in signals of engine Ne speed sensor and engine Bkup speed sensor circuit.
trouble
Action of
controller
Problem that
Engine stops.
appears on
machine The engine does not start.
Related
information

and standard
value in normal Defective connection of sen- Check Ne speed sensor and Bkup speed sensor directly for defec-
1
state sor connector tive connection (wrong connection).
40-320 4 WA320, 320PZ-6

Failure code [CA115] Engine Ne or Bkup speed sensor error SEN04191-00
WA320, 320PZ-6 40-320 5

SEN04191-00 Failure code [CA122] Charge pressure sensor high error
Failure code [CA122] Charge pressure sensor high error 1
Action code Failure code Charge pressure sensor high error

Trouble
Contents of
High voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor.
trouble
Action of Fixes charge pressure (boost pressure) and continues operation.
controller Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on Engine output drops.
machine
The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: ENGINE, 36500, CHG PRESS-A).
Related
The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
information
with the monitoring function (Code: ENGINE, 36502, CHG PRESS-A).

Defective sensor power sup- If failure code [CA227] is indicated simultaneously, carry out trouble-
1
ply 2 system shooting for it first.
Defective boost pressure BOOST PRESS & IMT Voltage
sensor and temperature sen-
2 Between (2) and (4) Voltage 4.75 5.25 V
sors [pressure signal system]
(Internal trouble) Voltage is measured with wiring harness connected. Accordingly, if
voltage is abnormal, check wiring harness and controller, too, for
another cause of trouble, and then judge.
Hot short (Short circuit with and carry out troubleshooting.
3 5V, 24V circuit) in wiring har- Wiring harness between EC1 (female) (44)
ness BOOST PRESS & IMT (female) (1) and Voltage Max. 1 V
Possible causes ground
state Short circuit in wiring har-
4 ness Wiring harnesses between EC1 (female)
(with another wiring harness) (44) BOOST PRESS & IMT (female) (1) Resis- Min.
and EC1 (female) (47) BOOST PRESS & tance 100 kz
IMT (female) (4).
Connecting parts among boost pressure sensor/temperature sen-
sor, engine wiring harness, and engine controller are suspected.
Defective wiring harness Inspect them directly.
5
connector Loose connector, broken lock and broken seal
Corrosive, bent, broken, forced-in, or extended pin
Humidity in connector, entry of dirt or dust, poor insulation
6 Defective engine controller EC1 Voltage
Between (37) and
Power supply 4.75 5.25 V
(47)
40-320 6 WA320, 320PZ-6

Failure code [CA122] Charge pressure sensor high error SEN04191-00
WA320, 320PZ-6 40-320 7

SEN04191-00 Failure code [CA123] Charge pressure sensor low error
Failure code [CA123] Charge pressure sensor low error 1
Action code Failure code Charge pressure sensor low error

Trouble
Contents of
Low voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor.
trouble
Action of Fixes charge pressure (boost pressure) and continues operation.
Problem that
machine
The input state (boost pressure) from the charge pressure sensor (boost pressure sensor) can be
checked with the monitoring function (Code: ENGINE, 36500, CHG PRESS-A).
Related
The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
information
with the monitoring function (Code: ENGINE, 36502, CHG PRESS-A).

1
Defective boost pressure BOOST PRESS & IMT Voltage
sensor or temperature sen-
2 Between (2) and (4) Power supply 4.75 5.25 V
sor [pressure signal circuit]
(Internal trouble) Voltage is measured with wiring harness connected. Accordingly, if
Grounding fault in wiring har- without turning starting switch ON.
3 ness Wiring harness between EC1 (female) (44)
(Contact with ground circuit) BOOST PRESS & IMT (female) (1) and Resis- Min.
tance 100 kz
4 ness Wiring harnesses between EC1 (female)
(with another wiring harness) (44) BOOST PRESS & IMT (female) (1), Resis- Min.
EC1 (female) (47) BOOST PRESS & IMT tance 100 kz
(female) (4)
5
connector Loose connector, broken lock and broken seal
Between (37) and
(47)
40-320 8 WA320, 320PZ-6

Failure code [CA123] Charge pressure sensor low error SEN04191-00
WA320, 320PZ-6 40-320 9

SEN04191-00 Failure code [CA131] Throttle sensor high error
Failure code [CA131] Throttle sensor high error 1
Action code Failure code Throttle sensor high error

Trouble
Contents of
High voltage was detected in the throttle sensor signal circuit.
trouble
Action of Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
Problem that
appears on The engine does not reach full throttle.
machine
The input state (accelerator pedal opening ratio) from the throttle sensor can be checked with the
monitoring function (Code: ENGINE, 31701, THROTTLE POS).
Related
The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
information
ENGINE, 31707, THROTTLE POS).

Defective throttle sensor If failure code [CA2185] is indicated simultaneously, carry out trou-
1
power supply system bleshooting for it first.
PD1 Accelerator pedal Voltage
All range
Between (1) and (3) 4.75 5.25 V
Defective accelerator pedal (Power supply)
2
(Internal trouble) When released 0.50 0.80 V
Between (2) and (3)
When pressed 3.70 4.00 V
Sensor voltage is measured with wiring harness connected. Accord-
ingly, if voltage is abnormal, check wiring harness and controller for
another cause of trouble before judgment
3 5V, 24V circuit) in wiring har-
Possible causes ness Wiring harness between EC2 (female) (9)
Voltage Max. 1 V
and standard PD1 (female) (2) and ground
state without turning starting switch ON.
Short circuit in wiring har-
(with another wiring harness) PD1 (female) (2), EC2 (female) (22) PD1 Resis- Min.
tance 100 kz
(female) (1)
Connecting parts among accelerator pedal, engine unit wiring har-
ness, and engine controller are suspected. Inspect them directly.
Defective wiring harness
5 Loose connector, broken lock, broken seal
connector
EC2 Accelerator pedal Voltage
6 Defective engine controller Between (22) and All range
4.75 5.25 V
(23) (Power supply)
When released 0.50 0.80 V
Between (9) and (23)
40-320 10 WA320, 320PZ-6

Failure code [CA131] Throttle sensor high error SEN04191-00
WA320, 320PZ-6 40-320 11

SEN04191-00 Failure code [CA132] Throttle sensor low error
Failure code [CA132] Throttle sensor low error 1
Action code Failure code Throttle sensor low error

Trouble
Contents of
Low voltage was detected in the throttle sensor signal circuit.
trouble
Problem that
machine
The input state (accelerator pedal opening ratio) from the throttle sensor can be checked with the
monitoring function (Code: ENGINE, 31701, THROTTLE POS).
Related
The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
information
ENGINE, 31707, THROTTLE POS).

Defective throttle sensor If failure code [CA2186] is indicated simultaneously, carry out trou-
1
power supply system bleshooting for it first.
PD1 Accelerator pedal Voltage
All range
Between (1) and (3) 4.75 5.25 V
Defective accelerator pedal (Power supply)
2
(Internal trouble) When released 0.50 0.80 V
Between (2) and (3)
Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
3
Possible causes (Short circuit with ground cir- Wiring harness between EC2 (female) (9) Resis- Min.
and standard cuit) PD1 (female) (2) and ground tance 100 kz
(with another wiring harness) PD1 (female) (2), EC2 (female) (23) PD1 Resis- Min.
tance 100 kz
(female) (3)
Connecting parts among fuel control dial, engine unit wiring har-
connector
EC2 Accelerator pedal Voltage
6 Defective engine controller Between (22) and All range
4.75 5.25 V
(23) (Power supply)
40-320 12 WA320, 320PZ-6

Failure code [CA132] Throttle sensor low error SEN04191-00
WA320, 320PZ-6 40-320 13

SEN04191-00 Failure code [CA144] Coolant sensor high error
Failure code [CA144] Coolant sensor high error 1
Action code Failure code Coolant sensor high error

Trouble
Contents of
High voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
Fixes engine coolant temperature and continues operation.
controller
Problem that
Exhaust smoke becomes white
appears on
machine Overheat prevention function does not function.
The input state (temperature) from the engine coolant temperature sensor can be checked with the
monitoring function (Code: ENGINE, 04104, COOLANT TEMP).
Related
The input state (voltage) from the engine coolant temperature sensor can be checked with the moni-
information
toring function (Code: ENGINE, 04105, COOLANT TEMP).

COOLANT TEMP
Coolant temperature Resistance
(male)
Defective coolant tempera-
1 ture sensor 0C 30 37 kz
(Internal trouble) 25C 9.3 10.7 kz
Between (A) and (B) 50C 3.2 3.8 kz
80C 1.0 1.3 kz
95C 700 800 z
ness Wiring harness between EC1 (female) (15) Resis-
2 Max. 10z
(Disconnection or defective COOLANT TEMP (female) (B) tance
contact in connector) Wiring harness between EC1 (female) (38) Resis-
Max. 10z
COOLANT TEMP (female) (A) tance
Possible causes
state 3 ness Wiring harness among all pins between EC1
(with another wiring harness) (female) (15) EC1 (female) Resis- Min.
(With all connectors of wiring harness distance 100 kz
connected)
Connecting parts among coolant temperature sensor, engine wiring
harness, and engine controller are suspected. Inspect them directly.
connector
EC1 (female) Coolant temperature Resistance
0C 30 37 kz
25C 9.3 10.7 kz
Between (15) and
50C 3.2 3.8 kz
(38)
80C 1.0 1.3 kz
95C 700 800 z
40-320 14 WA320, 320PZ-6

Failure code [CA144] Coolant sensor high error SEN04191-00
WA320, 320PZ-6 40-320 15

SEN04191-00 Failure code [CA145] Coolant sensor low error
Failure code [CA145] Coolant sensor low error 1
Action code Failure code Coolant sensor low error

Trouble
Contents of
Low voltage is detected in coolant temperature sensor signal circuit.
trouble
Action of
Fixes engine coolant temperature and continues operation.
controller
Problem that
Exhaust smoke becomes white
appears on
machine Overheat prevention function does not function.
The input state (temperature) from the engine coolant temperature sensor can be checked with the
monitoring function (Code: ENGINE, 04104, COOLANT TEMP).
Related
The input state (voltage) from the engine coolant temperature sensor can be checked with the moni-
information
toring function (Code: ENGINE, 04105, COOLANT TEMP).

COOLANT TEMP
Coolant temperature Resistance
(male)
0C 30 37 kz
Defective coolant tempera-
1 ture sensor 25C 9.3 10.7 kz
(Internal trouble) Between (A) and (B) 50C 3.2 3.8 kz
80C 1.0 1.3 kz
95C 700 800 z
Between (B) and
Possible causes All range Min. 100 kz
ground
and standard
value in normal Ground fault in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
state ness without turning starting switch ON.
2
(Short circuit with ground cir- Wiring harness between EC1 (female) (15) Resis- Min.
cuit) COOLANT TEMP (female) (B) and ground tance 100 kz
Short circuit in wiring har- without turning starting switch ON.
3 ness Wiring harness among all pins between EC1
(with another wiring harness) (female) (15) EC1 (female) (With all con- Resis- Min.
tance 100 kz
nectors of wiring harness disconnected)
Connecting parts among coolant temperature sensor, engine wiring
connector
40-320 16 WA320, 320PZ-6

Failure code [CA145] Coolant sensor low error SEN04191-00

EC1 (male) Coolant temperature Resistance
Possible causes 0C 30 37 kz
and standard
25C 9.3 10.7 kz
value in normal 5 Defective engine controller Between (15) and
state 50C 3.2 3.8 kz
(38)
80C 1.0 1.3 kz
95C 700 800 z
Between (15) and
All range Min. 100 kz
ground
WA320, 320PZ-6 40-320 17

SEN04191-00 Failure code [CA153] Charge temperature sensor high error
Failure code [CA153] Charge temperature sensor high error 1
Action code Failure code Charge temperature sensor high error

Trouble
Contents of High voltage is detected in temperature signal circuit of boost pressure sensor and temperature sen-
trouble sor.
Action of
Fixes charge temperature and continues operation.
controller
Problem that
Exhaust smoke becomes white.
appears on
machine Boost temperature-based engine protection function does not function.
The input state (temperature) from the charge temperature sensor (boost temperature sensor) can
be checked with the monitoring function (Code: ENGINE, 18500, CHG TEMP).
Related
The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
information
checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP).

BOOST PRESS &
Defective temperature sig- Charge temperature Resistance
IMT (male)
nal circuit of boost pressure
1 0C 29 36 kz
and temperature sensor
(Internal trouble) 25C 9 11 kz
Between (3) and (4)
40C 4.9 5.8 kz
100C 600 700 z
2 Max. 10z
(Disconnection or defective BOOST PRESS & IMT (female) (3) tance
Max. 10z
BOOST PRESS & IMT (female) (4) tance
Possible causes
value in normal Short circuit in wiring har- without turning starting switch ON.
tance 100 kz
4
connector Loose connector, broken lock, broken seal
EC1 (female) Charge temperature Resistance
5 Defective engine controller 0C 29 36 kz
Between (23) and 25C 9 11 kz
(47) 40C 4.9 5.8 kz
100C 600 700 z
40-320 18 WA320, 320PZ-6

Failure code [CA153] Charge temperature sensor high error SEN04191-00
WA320, 320PZ-6 40-320 19

SEN04191-00 Failure code [CA154] Charge temperature sensor low error
Failure code [CA154] Charge temperature sensor low error 1
Action code Failure code Charge temperature sensor low error

Trouble
Contents of Low voltage is detected in temperature signal circuit of boost pressure sensor and temperature sen-
trouble sor.
Action of
Fixes charge temperature and continues operation.
controller
Problem that
Exhaust smoke becomes white.
appears on
machine Boost temperature-based engine protection function does not function.
Related
information

BOOST PRESS &
Charge temperature Resistance
Defective temperature sig- IMT (male)
nal circuit of boost pressure 0C 29 36 kz
1 sensor and temperature sen-
25C 9 11 kz
sor Between (2) and (1)
(Internal trouble) 40C 4.9 5.8 kz
100C 600 700 z
Between (2) and
ground
Possible causes a Prepare with starting switch OFF, then carry out troubleshooting
and standard Ground fault in wiring har- without turning starting switch ON.
value in normal ness
2
state (Short circuit with ground cir- Wiring harness between EC1 (female) (23) Resis- Min.
cuit) BOOST PRESS & IMT (female) (3) and
tance 100 kz
ground
tance 100 kz
4
40-320 20 WA320, 320PZ-6

Failure code [CA154] Charge temperature sensor low error SEN04191-00

EC1 (female) Charge temperature Resistance
Possible causes
and standard 0C 29 36 kz
value in normal 5 Defective engine controller Between (23) and 25C 9 11 kz
state (47) 40C 4.9 5.8 kz
100C 600 700 z
Between (23) and
ground
WA320, 320PZ-6 40-320 21

SEN04191-00 Failure code [CA155] Derating of speed by abnormally high charge temperature
Failure code [CA155] Derating of speed by abnormally high charge

temperature 1
Action code Failure code Derating of speed by abnormally high charge temperature
Trouble
Contents of
Temperature signal of boost pressure sensor and temperature sensor is above upper control limit.
trouble
Action of Limits output and continues operation.
Problem that
Engine output drops.
appears on
machine Engine stops
Related
information

Cooling performance deterioration of the after cooler is suspected.
Inspect the following points directly.
Drop in cooling performance
Possible causes 1 Malfunction of hydraulic drive fan
of aftercooler
and standard Lack of cooling air
value in normal Clogged aftercooler fin
state Abnormally high tempera-
2 Inspect related parts directly.
ture at turbocharger outlet
If causes 1 2 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)
40-320 22 WA320, 320PZ-6

Failure code [CA155] Derating of speed by abnormally high charge temperature SEN04191-00
WA320, 320PZ-6 40-320 23

SEN04191-00 Failure code [CA187] Sensor power supply 2 low error
Failure code [CA187] Sensor power supply 2 low error 1
Action code Failure code Sensor power supply 2 low error

Trouble
Contents of
Low voltage is detected in sensor power supply 2 circuit.
trouble
Fixes boost pressure and continues operation.
Action of Fixes charge temperature and continues operation.
controller Limits output and continues operation.
Problem that
machine
Related
information

a Disconnect connector with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
Disconnect devices at Boost pressure, BOOST PRESS &
right in order. If mark temperature sensor IMT
Defective sensor or wiring E of failure code dis- Common rail
1 appears after repro- FUEL RAIL PRESS
harness pressure sensor
duction operation is
Possible causes conducted, that Bkup sensor CAM SENSOR
and standard device or wiring har-
value in normal Engine wiring
ness has a defect in EC1
state harness
it.
Connecting parts among each sensor, engine wiring harness, and
engine controller are suspected. Inspect them directly.
connector
40-320 24 WA320, 320PZ-6

Failure code [CA187] Sensor power supply 2 low error SEN04191-00
WA320, 320PZ-6 40-320 25

SEN04191-00 Failure code [CA221] Atmospheric pressure sensor high error
Failure code [CA221] Atmospheric pressure sensor high error 1
Action code Failure code Ambient pressure sensor high error

Trouble
Contents of
High voltage is detected in atmospheric pressure sensor circuit.
trouble
Action of
Fixes atmospheric pressure and continues operation.
controller
Problem that
Engine does not start easily.
appears on
machine Engine output drops.
The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: ENGINE, 37400, AMBIENT PRESS).
Related
The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 37402, AMBIENT PRESS).

1
AMBAIR PRESSURE Voltage
Defective atmospheric pres-
2
sure sensor (Internal trouble) Between (1) and (2) Power supply 4.75 5.25 V
Voltage is measured with wiring harness connected. Accordingly, if
3 5V, 24V circuit) in wiring har- Wiring harness between EC1 (female) (3)
ness AMBAIR PRESSURE (female) (3) and Voltage Max. 1 V
(with another wiring harness) AMBAIR PRESSURE (female) (3), EC1 Resis- Min.
(female) (33) AMBAIR PRESSURE tance 100 kz
(female) (1)
Connecting parts among atmospheric pressure sensor, engine wir-
ing harness, and engine controller are suspected. Inspect them
Defective wiring harness directly.
5
Between (33) and
(38)
40-320 26 WA320, 320PZ-6

Failure code [CA221] Atmospheric pressure sensor high error SEN04191-00
WA320, 320PZ-6 40-320 27

SEN04191-00 Failure code [CA222] Atmospheric sensor low error
Failure code [CA222] Atmospheric sensor low error 1
Action code Failure code Atmospheric sensor low error

Trouble
Contents of
Low voltage is detected in atmospheric pressure sensor circuit.
trouble
Action of
Fixes atmospheric pressure and continues operation.
controller
Problem that
Engine does not start easily.
appears on
The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: ENGINE, 37400, AMBIENT PRESS).
Related
The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 37402, AMBIENT PRESS).

1
AMBAIR PRESSURE Voltage
Defective atmospheric pres-
2
sure sensor (Internal trouble) Between (1) and (2) Power supply 4.75 5.25 V
Ground fault in wiring har- without turning starting switch ON.
ness
3
cuit) AMBAIR PRESSURE (female) (3) and
tance 100 kz
(with another wiring harness) AMBAIR PRESSURE (female) (3), EC1 Resis- Min.
(female) (38) AMBAIR PRESSURE tance 100 kz
(female) (2)
5
Between (33) and
(38)
40-320 28 WA320, 320PZ-6

Failure code [CA222] Atmospheric sensor low error SEN04191-00
WA320, 320PZ-6 40-320 29

SEN04191-00 Failure code [CA227] Sensor power supply 2 high error
Failure code [CA227] Sensor power supply 2 high error 1
Action code Failure code Sensor power supply 2 high error

Trouble
Contents of
High voltage is detected in sensor power supply 2 circuit.
trouble
Fixes boost pressure and continues operation.
Action of Fixes charge temperature and continues operation.
controller Limits output and continues operation.
Problem that
machine
Related
information

Possible causes engine controller are suspected. Inspect them directly.
and standard 1 Loose connector, broken lock, broken seal
connector
value in normal Corrosive, bent, broken, forced-in, or extended pin
state Humidity in connector, entry of dirt or dust, poor insulation
If cause 1 is not detected, engine controller may be defective.
40-320 30 WA320, 320PZ-6

Failure code [CA234] Engine overspeed SEN04191-00
Failure code [CA234] Engine overspeed 1
Action code Failure code Engine Overspeed

Trouble
Contents of
Engine speed is above upper control limit.
trouble
Action of Stops injection of injector until engine speed drops to normal level.
Problem that
appears on Engine speed fluctuates.
machine
Related Engine speed can be checked by monitoring function (Code: ENGINE, 01001, ENG SPEED).
information Method of reproducing failure code: Start engine and running at high idle.

1 Use of improper fuel Check fuel used directly.
Possible causes
and standard Improper way of speed con- Way of speed control may be improper. Teach proper way of use to
2
value in normal trol operator.
state If causes 1 and 2 are not detected, engine controller may be defec-
3 Defective engine controller tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
WA320, 320PZ-6 40-320 31

SEN04191-00 Failure code [CA238] Ne speed sensor power supply error
Failure code [CA238] Ne speed sensor power supply error 1
Action code Failure code Ne speed sensor supply power error

Trouble
Contents of
Low voltage is detected in engine Ne speed sensor power supply circuit.
trouble
Action of Controls Ne speed sensor with signals of Bkup speed sensor.
Problem that
Starting performance is poor.
appears on
machine There is hunting from engine.
Related
information

Disconnect devices at
right in order. If failure Ne speed sensor CRANK SENSOR
Defective sensor or wiring code disappears after
1
Possible causes harness reproduction opera-
and standard tion is conducted, that
value in normal device or wiring har- Engine wiring
state ness has a defect in EC1
harness
it.
connector
40-320 32 WA320, 320PZ-6

Failure code [CA271] IMV (IMA) Short circuit SEN04191-00
Failure code [CA271] IMV (IMA) Short circuit 1
Action code Failure code IMV (IMA) Short circuit

Trouble
Contents of
There is short circuit in supply pump actuator drive circuit.
trouble
Action of
controller
Problem that Engine speed does not rise from low idle.
machine Common rail fuel pressure is above command value.
Related
information

Defective supply pump actu- without turning starting switch ON.
1
ator CP3 PUMP REGULATOR (male) Resistance
Between (1) and ground Min. 100 kz
ness
2
cuit) CP3 PUMP REGULATOR (female) (1) and
tance 100 kz
ground
and standard Short circuit in wiring har- without turning starting switch ON.
value in normal 3 ness Wiring harness among all pins between EC1
state (with another wiring harness) (female) (2) EC1 (female) (With all connec- Resis- Min.
tance 100 kz
tors of wiring harness disconnected)
Connecting parts among supply pump actuator, engine wiring har-
connector
EC1 (female) Resistance
WA320, 320PZ-6 40-320 33

SEN04191-00 Failure code [CA272] IMV (IMA) Disconnection
Failure code [CA272] IMV (IMA) Disconnection 1
Action code Failure code IMV (IMA) Disconnection

Trouble
Contents of
There is disconnection in supply pump actuator drive circuit.
trouble
Action of
controller
Problem that
Engine runs, but in unstable condition.
appears on
machine Common rail fuel pressure is above command value.
Related
information

Defective supply pump actu- without turning starting switch ON.
1
ator CP3 PUMP REGULATOR (male) Resistance
Between (1) and (2) Max. 5 z
2 Max. 10 z
(Disconnection or defective CP3 PUMP REGULATOR (female) (1) tance
Max. 10 z
CP3 PUMP REGULATOR (female) (2) tance
Hot short (Short circuit with
Possible causes 3
24V circuit) in wiring harness Wiring harness between EC1 (female) (2)
and standard CP3 PUMP REGULATOR (female) (1) and Voltage Max. 3 V
value in normal ground
state
(with another wiring harness) (female) (2) EC1 (female) (With all connec- Resis- Min.
tance 100 kz
tors of wiring harness disconnected)
connector
40-320 34 WA320, 320PZ-6

Failure code [CA272] IMV (IMA) Disconnection SEN04191-00
WA320, 320PZ-6 40-320 35

SEN04191-00 Failure code [CA322] Injector #1 open/short error
Failure code [CA322] Injector #1 open/short error 1
Action code Failure code Injector #1 open/short error

Trouble
Contents of
There is disconnection or short circuit in drive circuit of injector No. 1.
trouble
Action of
controller
Problem that
There is irregular combustion or hunting.
appears on
Related
information

1 Defective injector No. 1 INJ CYL 1 Resistance
2 Max. 2 z
(Disconnection or defective INJ CYL 1 (1) tance
Max. 2 z
INJ CYL 1 (2) tance
3 ness
(Contact with ground circuit) Wiring harness between EC1 (female) (45) Resis-
Max. 2 z
INJ CYL 1 (1) and ground tance
and standard without turning starting switch ON.
value in normal
Wiring harness among all pins between EC1
state Short circuit in wiring har- Resis- Min.
(female) (45) EC1 (female) (With all con-
4 ness tance 100 kz
(with another wiring harness)
Resis- Min.
tance 100 kz
Connecting parts among injector No. 1, engine wiring harness, and
connector
Defective other cylinder If other failure codes are indicated simultaneously, carry out trouble-
6
injector or harness shooting for them.
7 Defective engine controller EC1 (female) Resistance
40-320 36 WA320, 320PZ-6

Failure code [CA322] Injector #1 open/short error SEN04191-00
WA320, 320PZ-6 40-320 37


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
Related
information

2 Max. 2 z
Max. 2 z
INJ CYL 5 (2) tance
3 ness
Max. 2 z
value in normal
4 ness tance 100 kz
Resis- Min.
tance 100 kz
connector
6
40-320 38 WA320, 320PZ-6

WA320, 320PZ-6 40-320 39


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
Related
information

2 Max. 2 z
Max. 2 z
INJ CYL 3 (1) tance
3 ness
Max. 2 z
value in normal
4 ness tance 100 kz
Resis- Min.
tance 100 kz
connector
6
40-320 40 WA320, 320PZ-6

WA320, 320PZ-6 40-320 41


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
Related
information

2 Max. 2 z
Max. 2 z
INJ CYL 6 (1) tance
3 ness
Max. 2 z
value in normal
4 ness tance 100 kz
Resis- Min.
tance 100 kz
connector
6
40-320 42 WA320, 320PZ-6

WA320, 320PZ-6 40-320 43


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
Related
information

2 Max. 2 z
Max. 2 z
INJ CYL 2 (2) tance
3 ness
Max. 2 z
value in normal
4 ness tance 100 kz
Resis- Min.
tance 100 kz
connector
6
40-320 44 WA320, 320PZ-6

WA320, 320PZ-6 40-320 45


Trouble
Contents of
trouble
Action of
controller
Problem that
appears on
Related
information

2 Max. 2 z
Max. 2 z
INJ CYL 4 (2) tance
3 ness
Max. 2 z
value in normal
4 ness tance 100 kz
Resis- Min.
tance 100 kz
connector
6
40-320 46 WA320, 320PZ-6

WA320, 320PZ-6 40-320 47

SEN04191-00 Failure code [CA342] Calibration code inconsistency
Failure code [CA342] Calibration code inconsistency 1
Action code Failure code Calibration code inconsistency

Trouble
Contents of
Matching error occurred in engine controller data.
trouble
Action of
controller
Problem that
Continues the normal operation.
appears on
machine Engine stops or does not start.
Related
information

and standard 1 Defect in related system If another code is displayed, carry out troubleshooting for it.
value in normal Possible defect in engine controller (Troubleshooting cannot be car-
state 2 Defective engine controller
ried out.)
40-320 48 WA320, 320PZ-6

Failure code [CA342] Calibration code inconsistency SEN04191-00
WA320, 320PZ-6 40-320 49

SEN04191-00 Failure code [CA351] Injectors drive circuit error
Failure code [CA351] Injectors drive circuit error 1
Action code Failure code Injectors drive circuit error

Trouble
Contents of
Abnormality occurred in injector drive power supply circuit.
trouble
Action of Limits output and continues operation (limits common rail pressure).
Exhaust smoke is black.
Problem that
There is irregular combustion.
appears on
The engine does not start.
Related
information

1 Defect in related system If another code is displayed, carry out troubleshooting for it.
Defective fuse No. 4 of fuse
2 If the fuse is broken, the circuit probably has a grounding fault, etc.
box FS1
Defective engine control cut-
Between (1) and (2) 200 400 z
out relay 1 (L107) (Internal
3 a Prepare with starting switch OFF, then turn starting switch ON
disconnection or short cir-
cuit) and carry out troubleshooting.
When engine control cut-out relay 1 (L107) is replaced with a relay
of the same type, if the condition becomes normal, the engine con-
trol cut-out relay 1 is defective.
Possible causes
and standard L108 (male) Resistance
Defective engine control cut-
value in normal Between (1) and (2) 200 400 z
out relay 2 (L108) (Internal
state 4 a Prepare with starting switch OFF, then turn starting switch ON
disconnection or short cir-
cuit) and carry out troubleshooting.
When engine control cut-out relay 2 (L108) is replaced with a relay
of the same type, if the condition becomes normal, the engine con-
trol cut-out relay 2 is defective.
Disconnection in wiring har- Wiring harness between fuse No. 4 of fuse Resis- Max.
ness box FS1 L107, L108 (female) (3) tance 0.5 z
5
(Disconnection or defective Wiring harness between L107 (female) (5), Resis- Max.
contact in connector) L108 (female) (5) EC3 (female) (3), (4) tance 0.5 z
Wiring harness between EC3 (female) (1), Resis- Max.
(2) ground tance 10 z
6 Defective engine controller (Since trouble is in the system, troubleshooting cannot be carried
out.)
40-320 50 WA320, 320PZ-6

Failure code [CA351] Injectors drive circuit error SEN04191-00
WA320, 320PZ-6 40-320 51

SEN04191-00 Failure code [CA352] Sensor power supply 1 low error
Failure code [CA352] Sensor power supply 1 low error 1
Action code Failure code Sensor power supply 1 low error

Trouble
Contents of
Low voltage is detected in sensor power supply 1 (5V) circuit.
trouble
Action of Fixes atmospheric pressure and continues operation.
Problem that
appears on
Related
information

Disconnect devices at Atmospheric pres-
AMBAIR PRESSURE
right in order. If failure sure sensor
Defective sensor or wiring code disappears after
1
harness reproduction opera-
tion is conducted, that Engine wiring
Possible causes device or wiring har- EC1
harness
and standard ness has a defect in
value in normal it.
state
2
40-320 52 WA320, 320PZ-6

Failure code [CA352] Sensor power supply 1 low error SEN04191-00
WA320, 320PZ-6 40-320 53

SEN04191-00 Failure code [CA386] Sensor power supply 1 high error
Failure code [CA386] Sensor power supply 1 high error 1
Action code Failure code Sensor power supply 1 high error

Trouble
Contents of
High voltage is detected in sensor power supply 1 (5V) circuit.
trouble
Action of Fixes atmospheric pressure and continues operation.
Problem that
appears on
Related
information

Possible causes directly.
and standard 1
value in normal
state
If cause 1 is not detected, engine controller may be defective.
40-320 54 WA320, 320PZ-6

Failure code [CA386] Sensor power supply 1 high error SEN04191-00
WA320, 320PZ-6 40-320 55

SEN04191-00

2008 KOMATSU
All Rights Reserved
40-320 56
SEN04192-02
WA320-6
WA320PZ-6
WA320-6 70001 and up


Failure code [CA428] Abnormally high level in water sensor.......................................................................... 4
Failure code [CA429] Abnormally low level in water sensor ........................................................................... 6
Failure code [CA431] Idle validation switch error............................................................................................ 8
Failure code [CA432] Idle validation action error .......................................................................................... 12
Failure code [CA435] Engine oil pressure switch error................................................................................. 16
Failure code [CA441] Battery voltage low error ............................................................................................ 17
Failure code [CA442] Battery voltage high error ........................................................................................... 20
Failure code [CA449] Common rail pressure high error 2 ............................................................................ 22
Failure code [CA451] Common rail pressure sensor high error.................................................................... 24
Failure code [CA452] Common rail pressure sensor low error ..................................................................... 26
Failure code [CA488] Derating of torque by abnormally high charge temperature....................................... 28
Failure code [CA553] Common rail pressure high error 1 ............................................................................ 29
Failure code [CA559] Supply pump pressure very low error ........................................................................ 30
Failure code [CA689] Engine Ne speed sensor error ................................................................................... 32
Failure code [CA731] Engine Bkup speed sensor phase error..................................................................... 34
Failure code [CA757] All continuous data lost error...................................................................................... 35
Failure code [CA778] Engine Bkup speed sensor error................................................................................ 38
Failure code [CA1633] KOMNET datalink timeout error ............................................................................... 40
Failure code [CA2185] Throttle sensor supply voltage high error ................................................................. 44
Failure code [CA2186] Throttle sensor power supply low error .................................................................... 46
Failure code [CA2249] Supply pump pressure very low error 2 ................................................................... 48
WA320, 320PZ-6 40-330 1

SEN04192-02
Failure code [CA2311] Abnormality in IMV (IMA) solenoid ........................................................................... 50

Failure code [CA2555] Intake heater relay disconnection error .................................................................... 52
Failure code [CA2556] Intake heater relay short circuit error........................................................................ 54
40-330 2 WA320, 320PZ-6

SEN04192-02
WA320, 320PZ-6 40-330 3

SEN04192-02 Failure code [CA428] Abnormally high level in water sensor
Failure code [CA428] Abnormally high level in water sensor 1
Action code Failure code Abnormally high level in water sensor

Trouble
Contents of
High voltage occurred in fuel water sensor
trouble
Action of
None in particular.
controller
Problem that
appears on Water separator monitor does not indicate normally.
machine
Related
information

1 Defective fuel water sensor
E42 (female) Resistance
Between (1) and (2) Max. 100 kz
ness Wiring harness between EC1 (female) (14) Resis- Max.
2
(Disconnection or defective E42 (male) (1) tance 100 kz
contact in connector) Wiring harness between EC1 (female) (47) Resis- Max.
E42 (male) (2) tance 100 kz
Possible causes
value in normal Short circuit in wiring har- without turning starting switch ON.
tance 100 kz
Connecting parts among fuel water sensor, engine wiring harness,
and engine controller are suspected. Inspect them directly.
connector
40-330 4 WA320, 320PZ-6

Failure code [CA428] Abnormally high level in water sensor SEN04192-02
WA320, 320PZ-6 40-330 5

SEN04192-02 Failure code [CA429] Abnormally low level in water sensor
Failure code [CA429] Abnormally low level in water sensor 1
Action code Failure code Abnormally low level in water sensor

Trouble
Contents of
Low voltage occurred in fuel water sensor
trouble
Action of
None in particular.
controller
Problem that
appears on Water separator monitor does not indicate normally.
machine
Related
information

1 Defective fuel water sensor E42 (female) Resistance
2 ness
(Contact with ground circuit) Wiring harness between EC1 (female) (14) Resis- Min.
E42 (male) (1) and ground tance 100 kz
state
tance 100 kz
Connecting parts among fuel water sensor, engine wiring harness,
connector
40-330 6 WA320, 320PZ-6

Failure code [CA429] Abnormally low level in water sensor SEN04192-02
WA320, 320PZ-6 40-330 7

SEN04192-02 Failure code [CA431] Idle validation switch error
Failure code [CA431] Idle validation switch error 1
Action code Failure code Idle validation switch error

Trouble
Contents of
Abnormality occurred in idle validation switch circuit
trouble
Action of
Operates at position of throttle of throttle sensor.
controller
Problem that
appears on
machine
The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring func-
tion (Code: ENGINE, 18300, IVS 1).
Related
information

PD1 Signal name Voltage
Defective accelerator pedal Between (5) and (4) Signal 1
1 See Fig. 1
(Internal trouble) Between (6) and (4) Signal 2
Wiring harness between EC2 (female) (11) Resis-
Max. 1 z
PD1 (female) (5) tance
Disconnection in wiring har- Wiring harness between EC2 (female) (1) Resis-
Max. 1 z
ness PD1 (female) (6) tance
Possible causes 2
and standard (Disconnection or defective Wiring harness between EC2 (female) (32) Resis-
value in normal PD1 (female) (4) tance
state Wiring harness between EC2 (female) (21) Resis-
Max. 1 z
Wiring harness between EC2 (female) (29) Resis-
Max. 1 z
Resis- Min.
(female) (11) EC2 (female) (PD1 and 2,
tance 100 kz
too, is disconnected.)
3 ness Resis- Min.
(female) (1) EC2 (female) (PD1 and 2, too,
(with another wiring harness) tance 100 kz
is disconnected.)
Between EC2 (female) (11) EC3 (female) Resis- Min.
(3), (4) (PD1 and 2, too, is disconnected.) tance 100 kz
Between EC2 (female) (1) EC3 (female) Resis- Min.
(3), (4) (PD1 and 2, too, is disconnected.) tance 100 kz
40-330 8 WA320, 320PZ-6

Failure code [CA431] Idle validation switch error SEN04192-02

connector
Possible causes
and standard
EC2 (female) Signal name Voltage
Between (11) and
Signal 1
(32) See Fig. 1
Between (1) and (32) Signal 2
WA320, 320PZ-6 40-330 9

SEN04192-02 Failure code [CA431] Idle validation switch error
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A: Voltage when pedal opened + 0.03 x
(Voltage when pedal pressed Voltage
when pedal opened)
B: Voltage when pedal opened + 0.1 x
when pedal opened)
40-330 10 WA320, 320PZ-6

Failure code [CA431] Idle validation switch error SEN04192-02
WA320, 320PZ-6 40-330 11

SEN04192-02 Failure code [CA432] Idle validation action error
Failure code [CA432] Idle validation action error 1
Action code Failure code Idle validation action error

Trouble
Contents of
Signals from the idle validation switch and throttle sensor do not agree (they are contradictory)
trouble
1. When the idle validation switch recognized the accelerator pedal is OFF and the throttle sensor, on
the contrary, recognized the accelerator pedal is ON: Control the opening ratio of the throttle to 0%
after the accelerator pedal is OFF and then control the opening ratio of the throttle to 50% while after
Action of the accelerator pedal is ON.
controller 2. When the idle validation switch recognized the accelerator pedal is ON and the throttle sensor, on
the contrary, recognized the accelerator pedal is OFF: Control the opening ratio of the throttle to 0%
(fix to the low idle).
Problem that
appears on Engine speed does not rise from low idle.
machine
Related
information
The input state from throttle position sensor can be checked with the monitoring function
(Code: ENGINE, 31701/31707, THROTTLE POS)

PD1 Signal name Voltage
When 0.50
released 0.80 V
Between (2) and (3) APS sig.
When 3.70
1 Defective accelerator pedal
pressed 4.00 V
Between (5) and (4) IVS 1
Possible causes See Fig. 1
and standard Between (6) and (4) IVS 2
value in normal Sensor voltage is measured with wiring harness connected. Accord-
state ingly, if voltage is abnormal, check wiring harness and controller for
Disconnection in wiring har- Wiring harness between EC2 (female) (22) Resis- Max.
ness PD1 (female) (1) tance 10 z
2
(Disconnection or defective Wiring harness between EC2 (female) (9) Resis- Max.
contact in connector) PD1 (female) (2) tance 10 z
Wiring harness between EC2(female) (21) Resis- Max.
PD2 (female) (1) tance 10 z
40-330 12 WA320, 320PZ-6

Failure code [CA432] Idle validation action error SEN04192-02

Resis- Min.
(female) (22) EC2 (female) (PD1 and 2,
tance 100 kz
Short circuit in wiring har- too, is disconnected.)
(with another wiring harness) (female) (9) EC2 (female) (PD1 and 2, too, Resis- Min.
tance 100 kz
is disconnected.)
Wiring harness between EC2 (female) (21)
Resis- Min.
EC2 (female) (PD1 and 2, too, is discon-
tance 100 kz
Possible causes nected.)
and standard Connecting parts among accelerator pedal, engine unit wiring har-
value in normal ness, and engine controller are suspected. Inspect them directly.
state Defective wiring harness
connector
EC2 (female) Accelelator pedal Voltage
Between (11) and
5 Defective engine controller Signal 1
(32) See Fig. 1
Between (1) and (32) Signal 2
WA320, 320PZ-6 40-330 13

SEN04192-02 Failure code [CA432] Idle validation action error
40-330 14 WA320, 320PZ-6

Failure code [CA432] Idle validation action error SEN04192-02
Fig. 1
Throttle: Throttle sensor signal voltage
Idle validation: Idle validation switch signal voltage
A: Voltage when pedal opened + 0.03 x
when pedal opened)
B: Voltage when pedal opened + 0.1 x
when pedal opened)
WA320, 320PZ-6 40-330 15

SEN04192-02 Failure code [CA435] Engine oil pressure switch error
Failure code [CA435] Engine oil pressure switch error 1
Action code Failure code Engine oil pressure switch error

Trouble
Contents of
Abnormality occurred in engine oil pressure switch signal circuit.
trouble
Action of
None in particular.
controller
Problem that
Engine oil switch-based engine protection function does not function.
appears on
Engine oil pressure monitor does not indicate normally.
machine
Related
Method of reproducing failure code: Starting switch ON or start engine
information

Defective engine oil pressure
1 OIL PRESSURE SWITCH (male) Resistance
switch
Between OIL PRESURE
Max. 10 z
SWITCH (male) and body
2
(Disconnection or defective Wiring harness between EC1 (female) (17) Resis-
OIL PRESSURE SWITCH (female) tance
state (with another wiring harness) (female) (17) EC1 (female) (With all con- Resis- Min.
tance 100 kz
Connecting parts among engine oil pressure switch, engine wiring
connector
Between (17) and ground Max. 10 z
40-330 16 WA320, 320PZ-6

Failure code [CA441] Battery voltage low error SEN04192-02
Failure code [CA441] Battery voltage low error 1
Action code Failure code Battery voltage low error

Trouble
Contents of
Low voltage (Max. 6 V) occurred in controller power supply voltage circuit.
trouble
Action of
controller
Problem that
Engine stops
appears on
Starting performance is poor
machine
Related
information

Loose, corroded battery ter-
1 Inspect battery terminal directly for loose and corrosion.
minal
a Prepare with starting switch OFF, then turn starting switch OFF
and START and carry out troubleshooting.
2 Defective battery voltage Battery (1 piece) Starting switch Voltage
Between (+) and () OFF Min. 12 V
terminals START Min. 6.2 V
Defective fuse No. 4 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
3
box FS1 (See cause 6.)
Defective engine control cut- Between (1) and (2) 200 400 z
4 out relay (L107) (Internal dis- a Prepare with starting switch OFF, then turn starting switch ON
connection or short circuit) and carry out troubleshooting.
Possible causes When engine control cut-out relay (L107) is replaced with a relay of
and standard the same type, if the condition becomes normal, the engine control
value in normal cut-out relay (L107) is defective.
state
When engine control cut-out relay (L108) is replaced with a relay of
the same type, if the condition becomes normal, the engine control
cut-out relay (L108) is defective.
Disconnection in wiring har- Wiring harness between fuse No. 4 of fuse Resis-
Max. 10 z
ness box FS1 L107, L108 (female) (3) tance
6
(Disconnection or defective Wiring harness between L107 (female) (5), Resis-
L108 (female) (5) EC3 (female) (3), (4) tance
Wiring harness between EC3 (female) (1), Resis-
Max. 10 z
(2) ground tance
WA320, 320PZ-6 40-330 17

SEN04192-02 Failure code [CA441] Battery voltage low error

Ground fault in wiring har- Wiring harness between fuse No. 4 of fuse
Resis- Min.
7 ness box FS1 L107, L108 (female) (3) and
tance 100 kz
(Contact with ground circuit) ground
Wiring harness between L107 (female) (5), Resis-
Max. 10z
L108 (female) (5) EC3 (3), (4) and ground tance
Wiring harness among pins between EC3
Resis- Min.
(female) (3), (4) EC3 (female) (1), (2)
tance 100 kz
Short circuit in wiring har- (With battery terminal disconnected)
Possible causes 8 ness Wiring harness among all pins between EC3
(with another wiring harness) (female) (3), (4) EC2 (female) Resis- Min.
and standard
tance 100 kz
value in normal (With battery terminal disconnected)
state Wiring harness among all pins between EC3
Resis- Min.
(female) (1), (2) EC2 (female)
tance 100 kz
(With battery terminal disconnected)
Connecting parts among fuse No. 4 of fuse box FS1, engine unit
wiring harness, and engine controller are suspected. Inspect them
9
10 Defective engine controller EC3 (female) Starting switch Voltage
Between (3), (4) and ON Min. 24 V
(1), (2) START Min. 12 V
40-330 18 WA320, 320PZ-6

Failure code [CA441] Battery voltage low error SEN04192-02
WA320, 320PZ-6 40-330 19

SEN04192-02 Failure code [CA442] Battery voltage high error
Failure code [CA442] Battery voltage high error 1
Action code Failure code Battery voltage high error

Trouble
Contents of
High voltage (min. 36V) occurred in controller power supply voltage circuit.
trouble
Action of
controller
Problem that
appears on Engine may stop.
machine
Related
information

1 Defective battery voltage
Battery Voltage
Between (+) and () terminals Less than 32 V
Possible causes a Prepare with starting switch OFF, then start engine and carry out
and standard troubleshooting.
value in normal 2 Defective alternator E02 (male) Engine speed Voltage
state
Between (1) and
Min. medium speed 27.5 29.5 V
ground
EC3 (female) Voltage
Between (3), (4) and (1), (2) Less than 32 V
40-330 20 WA320, 320PZ-6

Failure code [CA442] Battery voltage high error SEN04192-02
WA320, 320PZ-6 40-330 21

SEN04192-02 Failure code [CA449] Common rail pressure high error 2
Failure code [CA449] Common rail pressure high error 2 1
Action code Failure code Common rail pressure high error 2

Trouble
Contents of
Voltage (2) in common rail circuit is abnormally high.
trouble
Action of Limits output and continues operation (limits common rail pressure).
Problem that
Engine sound becomes larger under no load or light load.
appears on
machine
The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: ENGINE, 36400, RAIL PRESS).
Related
The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
information
function (Code: ENGINE, 36402, RAIL PRESS).

Commingling of air with the low pressure circuit is suspected.
Inspect the circuit directly in the following procedure.
1) Remove the pressure pickup plug (outlet side) of the fuel main fil-
2 Air in low-pressure circuit
ter.
2) Operate the feed pump of the fuel pre-filter.
3) Inspect leakage of fuel and air from the pressure pickup plug.
a For check of pressure in fuel return circuit, see Testing and
Defective fuel return circuit adjusting, Testing fuel pressure.
3
device Max. 0.02 MPa
Possible causes Fuel circuit pressure At low idle or cranking
and standard {Max. 0.19 kg/cm2}
value in normal a Prepare with starting switch ON, then carry out troubleshooting
state without turning starting switch OFF.
Defective common rail pres- Monitoring code
4 Monitoring information
sure sensor (Machine monitor)
Code: 36400, Condition when 0 0.39 MPa
RAIL PRESS engine stopped {0 4 kg/cm2}
For testing of leakage from pressure limiter, see Testing and adjust-
ing, Testing leakage from pressure limiter and return rate from
5 Defective pressure limiter injector.
Leakage from pres-
At low idle 0 cc (No leakage)
sure limiter
6 Defective supply pump If causes 1 5 are not detected, supply pump may be defective.
40-330 22 WA320, 320PZ-6

Failure code [CA449] Common rail pressure high error 2 SEN04192-02
WA320, 320PZ-6 40-330 23

SEN04192-02 Failure code [CA451] Common rail pressure sensor high error
Failure code [CA451] Common rail pressure sensor high error 1
Action code Failure code Common rail pressure sensor high error
Trouble
Contents of
High voltage occurred in common rail pressure sensor.
trouble
Problem that
appears on
Engine speed or output drops.
machine
Related
information

1
FUEL RAIL PRESS Voltage
Defective common rail pres-
sure sensor
3 5V, 24V circuit) in wiring har-
ness Wiring harness between EC1 (female) (25)
Voltage Max. 1 V
Possible causes FUEL RAIL PRESS (female) (2) and ground
(with another wiring harness) FUEL RAIL PRESS (female) (2), EC1 Resis- Min.
(female) (37) FUEL RAIL PRESS (female) tance 100 kz
(3)
Connecting parts among common rail pressure sensor, engine wir-
5
Between (37) and
(47)
40-330 24 WA320, 320PZ-6

Failure code [CA451] Common rail pressure sensor high error SEN04192-02
WA320, 320PZ-6 40-330 25

SEN04192-02 Failure code [CA452] Common rail pressure sensor low error
Failure code [CA452] Common rail pressure sensor low error 1
Action code Failure code Common rail pressure sensor low error
Trouble
Contents of
Low voltage occurred in common rail pressure sensor.
trouble
Problem that
appears on
Engine speed or output drops.
machine
Related
information

1
FUEL RAIL PRESS Voltage
Defective common rail pres-
sure sensor
Ground fault in wiring har- and carry out troubleshooting.
3 ness
Possible causes FUEL RAIL PRESS (female) (2) and ground tance 100 kz
(with another wiring harness) FUEL RAIL PRESS (female) (2), EC1 Resis- Min.
(female) (37) FUEL RAIL PRESS (female) tance 100 kz
(3)
Connecting parts among common rail pressure sensor, engine wir-
5
Between (37) and
(47)
40-330 26 WA320, 320PZ-6

Failure code [CA452] Common rail pressure sensor low error SEN04192-02
WA320, 320PZ-6 40-330 27

SEN04192-02 Failure code [CA488] Derating of torque by abnormally high charge temperature
Failure code [CA488] Derating of torque by abnormally high charge

temperature 1
Action code Failure code Derating of torque by abnormally high charge temperature
Trouble
Contents of
Temperature signal of boost pressure sensor and temperature sensor is above upper control limit.
trouble
Problem that
machine
The input state (boost temperature) from the boost pressure and temperature sensors can be
Related
The input state (boost temperature sensor voltage) from the boost pressure and temperature sen-
information
sors can be checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP).

Inspect following directly.
Drop in cooling performance Malfunction of hydraulic drive fan
Possible causes 1
of aftercooler Insufficient cooling air
and standard Clogged aftercooler fin
value in normal
state Abnormally high tempera-
2 Inspect related parts directly.
ture at turbocharger outlet
40-330 28 WA320, 320PZ-6

Failure code [CA553] Common rail pressure high error 1 SEN04192-02
Failure code [CA553] Common rail pressure high error 1 1
Action code Failure code Common rail pressure high error 1

Trouble
Contents of
Voltage (1) in common rail circuit is abnormally high.
trouble
Action of None in particular.
Problem that
Engine sound becomes larger under no load or light load.
appears on
machine
Related
information

Possible causes Inspect following directly for connection of ground terminal.

and standard Ground terminal (battery (-)) of machine main unit.
Defective connection of
value in normal 2 Ground terminal of engine
ground terminal
state Ground terminal of engine controller
Ground terminal of starting motor
Broken O-ring of supply
3 Inspect O-ring directly for breakage.
pump actuator
WA320, 320PZ-6 40-330 29

SEN04192-02 Failure code [CA559] Supply pump pressure very low error
Failure code [CA559] Supply pump pressure very low error 1
Action code Failure code Supply pump pressure very low error
Trouble
Contents of
No-pressure feed (1) occurred in common rail circuit.
trouble
Action of
controller
Problem that Engine does not start or starting performance is poor
appears on Exhaust smoke is black.
Related
information

Inspect for fuel leakage directly (visual inspection at engine low
1 Fuel leakage to outside
idle).
a For check of pressure in fuel low-pressure circuit, see Testing and
adjusting, Testing fuel pressure.
Cranking
0.3 1.1 MPa
Defective low-pressure cir- (When starting is not
2 {3.1 11.3 kg/cm2}
cuit device Pressure in fuel low- available)
pressure circuit At low idle
0.5 1.3 MPa
(When starting is
{5.1 13.3 kg/cm2}
available)
For testing of leakage from pressure limiter, see Testing and adjust-
ing, Testing leakage from pressure limiter and return rate from
3 Defective pressure limiter injector.
Leakage from pres-
At low idle 0 cc (No leakage)
Possible causes sure limiter
and standard a For testing of return rate from injector, see Testing and adjusting,
value in normal Testing leakage from pressure limiter and return rate from injec-
state tor.
Defective injector Cranking
4 (High-pressure piping in (When starting is not Max. 90 cc/min.
head included) Return rate from available)
injector At low idle
(When starting is Max. 180 cc/min.
available)
a For testing of return rate from supply pump, see Testing and
adjusting, Testing leakage-from pressure limiter and return rate
from injector.
Cranking
5 Defective supply pump (When starting is not Max. 140 cc/min.
Return rate from sup- available)
ply pump At low idle
(When starting is Max. 1,000 cc/min.
available)
40-330 30 WA320, 320PZ-6

Failure code [CA559] Supply pump pressure very low error SEN04192-02
WA320, 320PZ-6 40-330 31

SEN04192-02 Failure code [CA689] Engine Ne speed sensor error
Failure code [CA689] Engine Ne speed sensor error 1
Action code Failure code Engine Ne speed sensor error

Trouble
Contents of
Abnormality occurred in signals from engine Ne speed sensor.
trouble
Problem that There is hunting from engine.
appears on Starting performance is poor
Related
information

Defective Ne speed sensor If failure code [CA238] is indicated simultaneously, carry out trouble-
1
power supply system shooting for it first.
CRANK SENSOR Voltage
Defective engine Ne speed
sensor
Broken engine Ne speed
3 sensor or defective clear- Inspect engine Ne speed sensor for breakage or clearance.
ance
Broken rotation sensing fly-
4 Inspect it for breakage directly.
wheel
Possible causes
and standard 5
value in normal (Disconnection or defective Wiring harness between EC1 (female) (27) Resis- Max.
state contact in connector) CRANK SENSOR (female) (3) tance 10 z
6 ness
CRANK SENSOR (female) (3) and ground tance 100 kz
Hot short (Contact with 5V, and carry out troubleshooting.
7
Voltage Max. 1 V
CRANK SENSOR (female) (3) and ground
Short circuit in wiring har- Resis- Min.
CRANK SENSOR (female) (3), EC1 (female)
8 ness tance 100 kz
(16) CRANK SENSOR (female) (1)
Resis- Min.
CRANK SENSOR (female) (3), EC1 (female)
tance 100 kz
(48) CRANK SENSOR (female) (2)
40-330 32 WA320, 320PZ-6

Failure code [CA689] Engine Ne speed sensor error SEN04192-02

Connecting parts among engine Ne speed sensor, engine wiring
Possible causes connector
and standard Humidity in connector, entry of dirt or dust, poor insulation
value in normal
state
Between (16) and
(48)
WA320, 320PZ-6 40-330 33

SEN04192-02 Failure code [CA731] Engine Bkup speed sensor phase error
Failure code [CA731] Engine Bkup speed sensor phase error 1
Action code Failure code Engine Bkup speed sensor phase error
Trouble
Contents of
Abnormal phase is detected in signals of engine Ne speed sensor and engine Bkup speed sensor.
trouble
Problem that Engine does not start or is difficult to start.
appears on Idle speed is unstable.
machine Exhaust smoke is black.
Related
information

Broken engine Ne speed
1 Inspect engine Ne speed sensor for breakage directly.
sensor
Broken engine Bkup speed
2 Inspect engine Bkup speed sensor for breakage directly.
sensor
Inspect it for defect or breakage according to the following proce-
dure.
Defective/broken mount of
1) Set No. 1 cylinder to compression top dead center (align stamp-
3 rotation sensing flywheel on
ing mark).
crankshaft side
2) If tip of Ne speed sensor is aligned with center of oblong hole of
rotation sensing flywheel, it is mounted normally.
Possible causes
and standard Inspect it for defect or breakage according to the following proce-
value in normal dure.
state Defective/broken mount of 1) Set No. 1 cylinder to compression top dead center (align stamp-
4 rotation sensing ring on cam- ing mark).
shaft side 2) Remove Bkup speed sensor.
3) If 2 grooves (1 thread) of rotation sensing ring can be seen
through sensor mounting hole, it is mounted normally.
Defective timing between
5 Inspect crankshaft and camshaft for timing directly.
crankshaft and camshaft
Inspect following directly for connection of ground terminal.
Ground terminal (battery (-)) of machine main unit.
Defective connection of
6 Ground terminal of engine
ground terminal
Ground terminal of engine controller
Ground terminal of starting motor
40-330 34 WA320, 320PZ-6

Failure code [CA757] All continuous data lost error SEN04192-02
Failure code [CA757] All continuous data lost error 1
Action code Failure code All continuous data lost error

Trouble
Contents of
All data in engine controller are lost.
trouble
Action of
controller
Problem that Engine stops and sometimes cannot be started.
appears on The monitoring function of the machine monitor (engine controller system) sometimes fail to work
machine normally.
Related
information

Loose, corroded battery ter-
2 Inspect battery terminal directly for loose and corrosion.
minal
with starting switch OFF and START.
3 Defective battery voltage Battery (1 piece) Starting switch Voltage
Between (+) () ter- OFF Min. 12 V
minals START Min. 6.2 V
Defective fuse No. 4 of fuse
4 If the fuse is broken, the circuit probably has a grounding fault, etc.
box FS1
L107 (male) Resistance
Possible causes
and standard When engine control cut-out relay (L107) is replaced with a relay of
value in normal the same type, if the condition becomes normal, the engine control
state cut-out relay (L107) is defective.
When engine control cut-out relay (L108) is replaced with a relay of
the same type, if the condition becomes normal, the engine control
cut-out relay (L108) is defective.
Disconnection in wiring har- Wiring harness between fuse No. 4 of fuse Resis-
Max. 10z
ness box FS1 L107, L108 (female) (3) tance
7
(Disconnection or defective Wiring harness between L107 (female) (5), Resis-
contact in connector) Max. 10z
L108 (female) (5) EC3 (female) (3), (4) tance
Max. 10z
(2) ground tance
WA320, 320PZ-6 40-330 35

SEN04192-02 Failure code [CA757] All continuous data lost error

Connecting parts among fuse No. 4 of fuse box FS1, engine unit
wiring harness, and engine controller are suspected. Inspect them
8
Possible causes
and standard
value in normal
state a Prepare with starting switch OFF, then turn starting switch ON
9 Defective engine controller EC3 (female) Starting switch Voltage
ON Min. 24 V
Between (3) and (1)
START Min. 12 V
40-330 36 WA320, 320PZ-6

Failure code [CA757] All continuous data lost error SEN04192-02
WA320, 320PZ-6 40-330 37

SEN04192-02 Failure code [CA778] Engine Bkup speed sensor error
Failure code [CA778] Engine Bkup speed sensor error 1
Action code Failure code Engine Bkup speed sensor error

Trouble
Contents of
Abnormality is detected in signals of engine Bkup speed sensor.
trouble
Action of Controls Bkup speed sensor with signals of Ne speed sensor.
Problem that
Starting performance is poor
appears on
Engine output lowers.
machine
Related
information

1
CAM SENSOR Voltage
Defective engine Bkup
speed sensor
Broken engine Bkup speed
Inspect engine Bkup speed sensor directly for breakage or clear-
3 sensor or defective clear-
ance.
ance
4 Broken rotation sensing ring Inspect it for breakage directly.
Possible causes ness without turning starting switch ON.
and standard 5
(Disconnection or defective Wiring harness between EC1 (female) (26) Resis- Max.
value in normal contact in connector) CAM SENSOR (female) (3) tance 10 z
state
6 ness
CAM SENSOR (female) (3) and ground tance 100 kz
7
Voltage Max. 1 V
CAM SENSOR (female) (3) and ground
Short circuit in wiring har- Resis- Min.
CAM SENSOR (female) (3), EC1 (female)
8 ness tance 100 kz
(37) CAM SENSOR (female) (1)
Resis- Min.
CAM SENSOR (female) (3), EC1 (female)
tance 100 kz
(47) CAM SENSOR (female) (2)
40-330 38 WA320, 320PZ-6

Failure code [CA778] Engine Bkup speed sensor error SEN04192-02

Connecting parts among engine Bkup speed sensor, engine wiring
Possible causes connector
and standard Humidity in connector, entry of dirt or dust, poor insulation
value in normal
state
Between (37) and
(47)
WA320, 320PZ-6 40-330 39

SEN04192-02 Failure code [CA1633] KOMNET datalink timeout error
Failure code [CA1633] KOMNET datalink timeout error 1
Action code Failure code KOMNET datalink timeout error

Trouble
Contents of Engine controller detected a communication error in the KOMNET communication circuit used for the
trouble communication between the HST controller and machine monitor.
Continues the operation from the default mode.
Action of
controller
If problem is removed, system is returned to normal operating state.
Problem that
KOMNET communication information may not be transmitted correctly to cause incorrect operation
appears on
of machine. (Problem depends on failure occurrence location.)
machine
Related If failure code [DAJRKR] is indicated simultaneously, carry out troubleshooting for it first.
information Method of reproducing failure code: Turn the starting switch ON.

CAN1 (male) Resistance
Defective CAN end point Between (A) and (B) 110 140 z
1
resistance a Prepare with starting switch OFF, then carry out troubleshooting
Between (A) and (B) 110 140 z
Possible causes
state Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) HST (female) (28), (38) tance
Disconnection in wiring har- Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
ness (47) L29 (female) (3), (8) tance
2
(Disconnection or defective Wiring harness between EC2 (female) (46), Resis-
(47) L80 (female) (7), (8) tance
Max. 1 z
(47) CAN1 (female) (A), (B) tance
Max. 1 z
40-330 40 WA320, 320PZ-6

Failure code [CA1633] KOMNET datalink timeout error SEN04192-02

Min. 1 Mz
(47) HST (female) (28), (38) and ground tance
Ground fault in wiring har- Wiring harness between EC2 (female) (46), Resis-
Min. 1 Mz
ness (47) L29 (female) (3), (8) and ground tance
3
Possible causes (Short circuit with ground cir- Wiring harness between EC2 (female) (46), Resis-
and standard cuit) Min. 1 Mz
(47) L80 (female) (7), (8) and ground tance
value in normal
state Min. 1 Mz
(47) CAN1 (female) (A), (B) and ground tance
Min. 1 Mz
a If above troubleshootings 1 3 have not identified the cause of
Defective machine monitor, the trouble, failure on the machine monitor, HST controller,
4 HST controller, engine con- engine controller or KOMTRAX terminal should be suspected.
troller or KOMTRAX terminal (Since trouble is in system, troubleshooting cannot be carried
out.)
WA320, 320PZ-6 40-330 41

SEN04192-02 Failure code [CA1633] KOMNET datalink timeout error
40-330 42 WA320, 320PZ-6

Failure code [CA1633] KOMNET datalink timeout error SEN04192-02
WA320, 320PZ-6 40-330 43

SEN04192-02 Failure code [CA2185] Throttle sensor supply voltage high error
Failure code [CA2185] Throttle sensor supply voltage high error 1
Action code Failure code Throttle sensor supply voltage high error
Trouble
Contents of
High voltage (min. 5.25V) occurred in throttle sensor power supply circuit.
trouble
Problem that
machine
Related
information

Short circuit in wiring har- Wiring harness among all pins between EC2
Resis- Min.
1 ness (female) (22) EC2 (female) (PD1 and 2,
tance 100 kz
(with another wiring harness) too, is disconnected.)
Possible causes
and standard Between EC2 (female) (22) EC3 (female) Resis- Min.
value in normal (3) (PD1 and 2, too, is disconnected.) tance 100 kz
state Connecting parts among accelerator pedal dial, engine unit wiring
connector
40-330 44 WA320, 320PZ-6

Failure code [CA2185] Throttle sensor supply voltage high error SEN04192-02
WA320, 320PZ-6 40-330 45

SEN04192-02 Failure code [CA2186] Throttle sensor power supply low error
Failure code [CA2186] Throttle sensor power supply low error 1
Action code Failure code Throttle sensor power supply voltage low error
Trouble
Contents of
Low voltage occurred in throttle sensor power supply circuit.
trouble
Problem that
machine
Related
information

1 ness
PD1 (female) (1) and ground tance 100 kz
Possible causes
and standard 2 ness Wiring harness among all pins between EC2
(with another wiring harness) (female) (9) EC2 (female) (PD1 and 2, too, Resis- Min.
value in normal tance 100 kz
state is disconnected.)
connector
40-330 46 WA320, 320PZ-6

Failure code [CA2186] Throttle sensor power supply low error SEN04192-02
WA320, 320PZ-6 40-330 47

SEN04192-02 Failure code [CA2249] Supply pump pressure very low error 2
Failure code [CA2249] Supply pump pressure very low error 2 1
Action code Failure code Supply pump pressure very low error 2
Trouble
Contents of
No-pressure feed (2) occurred in common rail circuit.
trouble
Problem that Starting performance is poor
appears on Exhaust smoke is black.
machine Engine output lowers.
Related
information

and standard
value in normal 1 Carry out troubleshooting for failure code [CA559].
state
40-330 48 WA320, 320PZ-6

Failure code [CA2249] Supply pump pressure very low error 2 SEN04192-02
WA320, 320PZ-6 40-330 49

SEN04192-02 Failure code [CA2311] Abnormality in IMV (IMA) solenoid
Failure code [CA2311] Abnormality in IMV (IMA) solenoid 1
Action code Failure code Abnormality in IMV (IMA) solenoid

Trouble
Contents of
Resistance in supply pump actuator circuit is abnormally high or low.
trouble
Action of
controller
Problem that
machine
Related
information

Defective supply pump actu- CP3 PUMP REGULATOR (male) Resistance
2
ator
3 Max. 5 z
(Disconnection or defective CP3 PUMP REGULATOR (female) (1) tance
Possible causes Max. 5 z
CP3 PUMP REGULATOR (female) (2) tance
and standard
value in normal
state
(Contact with ground circuit) CP3 PUMP REGULATOR (female) (1) and Resis- Min.
tance 100 kz
ground
connector
40-330 50 WA320, 320PZ-6

Failure code [CA2311] Abnormality in IMV (IMA) solenoid SEN04192-02
WA320, 320PZ-6 40-330 51

SEN04192-02 Failure code [CA2555] Intake heater relay disconnection error
Failure code [CA2555] Intake heater relay disconnection error 1
Action code Failure code Intake heater relay disconnection error

Trouble
Contents of
There is disconnection in intake air heater relay.
trouble
Action of
None in particular.
controller
Problem that
Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temper-
appears on
ature)
machine
The input state (boost temperature) can be checked with the monitoring function (Code: ENGINE,
Related 18500, CHG TEMP)
information Method of reproducing failure code: Turn the starting switch ON when boost temperature is 4C or
less.

without turning starting switch ON. (Test relay unit).
Resistance
Between E06 and ground
Defective heater relay 300 600 z
1
(Internal disconnection) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Test by replacing relay unit.)
When heater relay is replaced with a relay of the same type, if the
condition becomes normal, the heater relay is defective.
ness Wiring harness between EC2 (female) (40) Resis- Max.
2
(Disconnection or defective E06 tance 10 z
Possible causes
contact in connector) Wiring harness between heater relay R90 Resis- Max.
and standard
value in normal R20 tance 10 z
state a Prepare with starting switch OFF, then carry out troubleshooting
(with another wiring harness) (female) (40) EC2 (female) (E06, too, is Resis- Min.
tance 100 kz
disconnected.)
Connecting parts among heater relay, engine unit wiring harness,
connector
Between (40) and ground 300 600 z
40-330 52 WA320, 320PZ-6

Failure code [CA2555] Intake heater relay disconnection error SEN04192-02
WA320, 320PZ-6 40-330 53

SEN04192-02 Failure code [CA2556] Intake heater relay short circuit error
Failure code [CA2556] Intake heater relay short circuit error 1
Action code Failure code Intake heater relay short circuit error
Trouble
Contents of
There is short circuit in intake air heater relay.
trouble
Action of
None in particular.
controller
Problem that
Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temper-
appears on
ature)
machine
The input state (boost temperature) can be checked with the monitoring function (Code: ENGINE,
Related 18500, CHG TEMP)
information Method of reproducing failure code: Turn the starting switch ON when boost temperature is 4C or
less.

without turning starting switch ON. (Test relay unit).
Resistance
Between E06 and ground
Defective heater relay 300 600 z
1
(Internal short circuit) a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting. (Test by replacing relay unit.)
When heater relay is replaced with a relay of the same type, if the
condition becomes normal, the heater relay is defective.
2 ness
Possible causes (Contact with ground circuit) Wiring harness between EC2 (female) (40) Resis- Min.
and standard E06 tance 100 kz
state Short circuit in wiring har- without turning starting switch ON.
(with another wiring harness) (female) (40) EC2 (female) (E06, too, is Resis- Min.
tance 100 kz
disconnected.)
Connecting parts among heater relay, engine unit wiring harness,
connector
Between (40) and ground 300 600 z
40-330 54 WA320, 320PZ-6

Failure code [CA2556] Intake heater relay short circuit error SEN04192-02
WA320, 320PZ-6 40-330 55

SEN04192-02

2010 KOMATSU
All Rights Reserved
40-330 56
SEN04193-01
WA320-6
WA320PZ-6
WA320-6 70001 and up


Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short ............................................................. 2
Failure code [D192KY] ECSS solenoid relay: Hot short ................................................................................. 4
Failure code [D1B0KA] HST safety relay: Disconnection ............................................................................... 6
Failure code [D1B0KB] HST safety relay: Ground fault .................................................................................. 8
Failure code [D1B0KY] HST safety relay: Hot short ..................................................................................... 10
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection ............................................................. 12
Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection.................................................. 14
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection ................................................ 16
Failure code [DAJ0KK] HST controller power supply: Low voltage .............................................................. 20
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality .................................................... 22
Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault................................... 24
Failure code [DAJ1L6] HST controller main power line: Hot short................................................................ 26
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage ....................................................... 28
Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness............. 30
Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault............ 32
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range......................................................... 34
Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals............. 36
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection..................................................... 37
Failure code [DAJRMA] HST controller: Disagreement in option selection .................................................. 43
WA320, 320PZ-6 40-340 1

SEN04193-01 Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short
Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short

Action code Failure code Backup alarm/lamp relay 1 circuit: Hot short
Trouble
E01 D160KY (Machine monitor system)
Contents of Since there is hot short in backup alarm/lamp relay 1 output system, backup lamp relay 1 does not
trouble operate.
Turns output to backup alarm/lamp relay 1 OFF.
Action of
If hot short occurs while alarm buzzer is in operation, output is turned OFF.
machine monitor
If hot short occurs while ECSS is in operation, output is turned OFF.
Backup lamp is kept ON.
Problem that
Backup alarm is kept ON.
appears on
Alarm buzzer may not sound.
machine
ECSS may not operate.
Output state (ON/OFF) to backup alarm/lamp relay 1 can be checked with monitoring function.
(Monitoring code: MONITOR PANEL 40952 D-OUT-2)
Operating condition of alarm buzzer can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL 40952 D-OUT-0)
information Operating condition of ECSS can be checked with monitoring function.
Method of reproducing failure code: Turn starting switch ON + Set FNR (directional) lever or switch to
R (Reverse) position.

troubleshooting.
Condition becomes Relay (L109) is
Replace backup lamp normal. defective.
relay (L109) with
Defective backup alarm/lamp another relay. Condition does not Relay (L109) is
1
relay (L109) (Internal defect) become normal. normal
Possible causes
and standard
value in normal Resis- 200 400
Between L109 (male) (1) (2)
state tance z
Hot short (Contact with 5 V, without turning starting switch ON.
2 24 V circuit) in wiring har- (Set FNR (directional) lever or switch to R (Reverse) position.)
ness Wiring harness between L24 (female) (12)
Voltage Max. 1 V
L109 (female) (2)
3 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
40-340 2 WA320, 320PZ-6

Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short SEN04193-01
WA320, 320PZ-6 40-340 3

SEN04193-01 Failure code [D192KY] ECSS solenoid relay: Hot short
Failure code [D192KY] ECSS solenoid relay: Hot short

Action code Failure code ECSS solenoid relay: Hot short
Trouble
E01 D192KY (Machine monitor system)
Contents of Since there is hot short in ECSS solenoid relay output system, ECSS solenoid relay does not oper-
trouble ate.
Turns output to ECSS solenoid relay OFF.
Action of
If hot short occurs while backup alarm/lamp is in operation, output is turned OFF.
machine monitor
If hot short occurs while alarm buzzer is in operation, output is turned OFF.
Problem that ECSS does not operate.
appears on Backup alarm/lamp may not sound.
machine Alarm buzzer may not operate.
Output state (ON/OFF) to ECSS solenoid relay can be checked with monitoring function.
Operating condition of backup alarm/lamp can be checked with monitoring function.
information Operating condition of alarm buzzer can be checked with monitoring function.
This fault is not detected if ECSS is not installed.
Method of reproducing failure code: Travel at speed higher than 5 km/h.

troubleshooting.
Replace ECSS sole- normal. defective.
noid relay (L110) with
Defective ECSS solenoid another relay. Condition does not Relay (L110) is
1
relay (L110) (Internal defect) become normal. normal.
value in normal Resis- 200 400
state Between L110 (male) (1) (2)
tance z
Hot short (Contact with 5 V, and carry out troubleshooting.
2 24 V circuit) in wiring har-
ness Between wiring harness L24 (female) (11)
Voltage Max. 1 V
L110 (female) (2) and ground
3 Defective machine monitor tive. (Since trouble is in system, troubleshooting cannot be carried
out.)
40-340 4 WA320, 320PZ-6

Failure code [D192KY] ECSS solenoid relay: Hot short SEN04193-01
WA320, 320PZ-6 40-340 5

SEN04193-01 Failure code [D1B0KA] HST safety relay: Disconnection
Failure code [D1B0KA] HST safety relay: Disconnection

Action code Failure code HST safety relay: Disconnection
Trouble
E03 D1B0KA (HST controller system)
Contents of
Disconnection was detected in HST safety relay circuit when starting switch is turned ON.
trouble
Turns clutch EPC solenoid output OFF.
Turns motor 1 solenoid output OFF.
Action of
Turns HST safety relay output OFF.
machine monitor
Even if trouble disappears, system does not reset itself until starting switch is turned OFF.
Traction force decreases.
Problem that
Travel speed is not limited with speed range selector switch and travel speed control dial.
appears on
If engine is stopped without applying parking brake securely on slope, machine moves down sud-
machine
denly.
If [DAJ2L3] or [DAJ2L4] is displayed, carry out troubleshooting for it first.
Following output command values can be checked with monitoring function.
Related
Motor 1 solenoid output: HST 80000 MOTOR SOL DIR (mA)
information
HST safety relay output: HST 40979 D_OUT_15 (ON/OFF)
Clutch EPC solenoid output: HST 80100 CLUTCH SOL DIR (mA)

troubleshooting.
Replace HST safety normal. defective.
relay (L111) with
Defective HST safety relay another relay. Condition does not Relay (L111) is
1
(Internal defect) become normal. normal.
Resis- 200 400
tance z
troubleshooting.
Replace VIS power Condition becomes Relay (L102) is
supply holding relay normal. defective.
Possible causes Defective VIS power supply (L102) with another Condition does not Relay (L102) is
and standard 2 holding relay (Internal short relay. become normal. normal.
value in normal circuit)
Resis- 200 400
tance z
Disconnection in wiring har- Wiring harness between HST (female) (17) Resis-
Max. 1 z
ness (Disconnection in wiring L111 (female) (2) tance
3
or defective contact in con- Wiring harness between L102 (female) (3) Resis-
nector) Max. 1 z
L111 (female) (1) tance
Wiring harness between fuse FS1 (No. 3) Resis-
Max. 1 z
4 Defective HST controller
HST Voltage
Between (17) ground Max. 1 V
40-340 6 WA320, 320PZ-6

Failure code [D1B0KA] HST safety relay: Disconnection SEN04193-01
WA320, 320PZ-6 40-340 7

SEN04193-01 Failure code [D1B0KB] HST safety relay: Ground fault
Failure code [D1B0KB] HST safety relay: Ground fault

Action code Failure code HST safety relay: Ground fault
Trouble
E01 D1B0KB (HST controller system)
Contents of
Ground fault was detected in HST safety relay circuit when starting switch is turned ON.
trouble
Action of
machine monitor
Problem that
appears on
machine
denly.
Related Motor 1 solenoid output: HST 80000 MOTOR SOL DIR (mA)
information HST safety relay output: HST 40979 D_OUT_15 (ON/OFF)
Clutch EPC solenoid output: HST 80100 CLUTCH SOL DIR (mA).

troubleshooting.
relay (L111) with
1
Possible causes
and standard
value in normal
state Resis- 200 400
tance z
2 ness (Contact with GND cir-
cuit) Between wiring harness (HST (female) (17) Resis-
Min. 1 Mz
L111 (female) (2) and ground tance
If causes 1 and 2 are not detected, HST controller may be defective.
40-340 8 WA320, 320PZ-6

Failure code [D1B0KB] HST safety relay: Ground fault SEN04193-01
WA320, 320PZ-6 40-340 9

SEN04193-01 Failure code [D1B0KY] HST safety relay: Hot short
Failure code [D1B0KY] HST safety relay: Hot short

Action code Failure code HST safety relay: Hot short
Trouble
E03 D1B0KY (HST controller system)
Contents of
Hot short was detected in HST safety relay circuit.
trouble
Action of
machine monitor
Problem that
appears on
machine
denly.
If [DAJ2L3] or [DAJ2L4] is displayed, carry out troubleshooting for it first.
Related
information
Clutch EPC solenoid output: HST 80100 CLUTCH SOL DIR (mA).

troubleshooting.
relay (L111) with
1
Possible causes
and standard
value in normal
state Resis- 200 400
tance z
ness Between wiring harness HST (female) (17)
Voltage Max. 1 V
If causes 1 and 2 are not detected, HST controller may be defective.
40-340 10 WA320, 320PZ-6

Failure code [D1B0KY] HST safety relay: Hot short SEN04193-01
WA320, 320PZ-6 40-340 11

SEN04193-01 Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection
Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection

Action code Failure code IGN C system: Ground fault/Disconnection
Trouble
E01 D5ZHL6 (Machine monitor system)
Machine monitor detected disconnection or ground fault in C terminal system.
(When engine speed is above 500 rpm and there is alternator R terminal voltage and starting switch
Contents of
is ON, there is not C terminal signal input.)
trouble
a If engine speed above 250 rpm is sensed in 3 seconds after starting switch is turned ON, however,
error is not detected.
Action of None in particular.
machine monitor When starting switch is turned OFF after trouble is repaired, system is reset.
Problem that
appears on Engine cannot be started (It may be able to be started, depending on faulty part).
machine
Input state (ON/OFF) from starting switch C terminal to machine monitor be checked with monitoring
Related function.
information (MONITOR PANEL 40900 D-IN-2)
Method of reproducing failure code: Turn starting switch to START position.

a Prepare with starting switch OFF, then turn starting switch to ON/
OFF/START position and carry out troubleshooting.
Defective starting switch Starting switch
1 L02 Voltage
(Internal defect) position
START 20 30 V
Between (3) ground
OFF/ON Max. 1 V
Disconnection in wiring har- Wiring harness between L106 (female) (5) Resis-
Max. 1 z
ness (Disconnection in wiring L25 (female) (2) tance
2
or defective contact in con- Wiring harness between L02 (female) (3) Resis-
nector) Max. 1 z
Possible causes
Wiring harness between L79 (female) (6) Resis-
and standard Max. 1 z
value in normal
Between wiring harness L02 (female) (3) Resis-
Ground fault in wiring har- Min. 1 Mz
cuit) Between wiring harness L79 (female) (6) Resis-
Min. 1 Mz
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch to ON/
OFF/START position and carry out troubleshooting.
Starting switch
4 Defective machine monitor L25 Voltage
position
START 20 30 V
Between (2) ground
OFF/ON Max. 1 V
40-340 12 WA320, 320PZ-6

Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection SEN04193-01
WA320, 320PZ-6 40-340 13

SEN04193-01 Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection
Failure code [DAF3KK] UNSW power supply: Ground fault/

Disconnection
Action code Failure code UNSW power supply: Ground fault/Disconnection
Trouble
E01 DAF3KK (Machine monitor system)
Contents of When accessory power supply (power supply for operation) voltage is above 17 V, UNSW power
trouble supply (power supply for memory) has ground fault.
Action of
None in particular.
machine monitor
Problem that Service meter time gains or loses.
appears on Odometer does not advance.
machine Fault history data is not saved.
Related
Method of reproducing failure code: Turn starting switch ON.
information

Possible causes 1 ness (Contact with GND cir-
cuit) Between wiring harness battery relay R01 Resis-
and standard Min. 1 Mz
L24 (female) (4), (5) and ground tance
value in normal
Between L24 (female) (4), (5) (9), (10),
Voltage 20 30 V
(17), (18), (19), (20)
40-340 14 WA320, 320PZ-6

Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection SEN04193-01
WA320, 320PZ-6 40-340 15

SEN04193-01 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection
Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection

Action code Failure code Machine monitor CAN-NET Signal: Disconnection
Trouble
E03 DAFRKR (HST controller system)
Contents of
HST controller cannot get information from machine monitor
trouble
Action of
Uses CAN information that was sent from machine monitor before the occurrence of the error.
machine monitor
Problem that
appears on The monitor does not display normally
machine
Related
information

1
value in normal Wiring harness between HST (female) (28), Resis-
Max. 1 z
state (38) L80 (female) (7), (8) tance
Wiring harness between HST (female) (28), Resis-
Max. 1 z
Disconnection in wiring har- (38) L29 (female) (3), (8) tance
ness Wiring harness between HST (female) (28), Resis-
2 Max. 1 z
(Disconnection or defective (38) EC2 (female) (46), (47) tance
contact in connector) Wiring harness between HST (female) (28), Resis-
Max. 1 z
(38) C140 (female) (28), (38) tance
Max. 1 z
Max. 1 z
40-340 16 WA320, 320PZ-6

Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection SEN04193-01

Min. 1 Mz
Min. 1 Mz
Grounding fault in wiring har-
3 ness (Contact with ground Min. 1 Mz
(38) EC2 (female) (46), (47) and ground tance
circuit)
Possible causes Wiring harness between HST (female) (28), Resis-
Min. 1 Mz
and standard (38) C140 (female) (28), (38) and ground tance
Min. 1 Mz
state (38) CAN1 (female) (A), (B) and ground tance
Min. 1 Mz
a Power supply circuit or grounding circuit may be defective.
Defective power supply cir-
4 Confirm that there is no disconnection of the circuit or defective
cuit of machine monitor
mating of the connector.
out.)
WA320, 320PZ-6 40-340 17

SEN04193-01 Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection
40-340 18 WA320, 320PZ-6

Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection SEN04193-01
WA320, 320PZ-6 40-340 19

SEN04193-01 Failure code [DAJ0KK] HST controller power supply: Low voltage
Failure code [DAJ0KK] HST controller power supply: Low voltage

Action code Failure code HST controller power supply: Low voltage
Trouble
E03 DAJ0KK (HST controller system)
Low voltage was detected in HST controller power supply.
Contents of
(While engine was running and alternator voltage was above 20 V, controller voltage was below 18
trouble
V.)
Turns all outputs OFF.
Action of
Trouble which may be detected wrongly is not detected.
machine monitor
Problem that
Machine cannot travel (in either direction).
appears on
Another trouble may be detected.
machine
Related If gear is set in neutral and engine is restarted while controller voltage is above 20 V, system is reset.
information Method of reproducing failure code: Turn starting switch ON

1 Defective (Broken) fuse Check fuse FS1 (No. 3) directly.
Possible causes ness (Disconnection in wiring Wiring harness between HST (female) (1) Resis-
2 Max. 1 z
and standard or defective contact in con- fuse FS1 (No. 3) tance
value in normal nector) Wiring harness between HST (female) (11) Resis-
state Max. 1 z
fuse FS1 (No. 3) tance
HST Voltage
Between (1), (11) ground 20 30 V
40-340 20 WA320, 320PZ-6

Failure code [DAJ0KK] HST controller power supply: Low voltage SEN04193-01
WA320, 320PZ-6 40-340 21

SEN04193-01 Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality
Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality

Action code Failure code HST controller memory (EEPROM): Abnormality
Trouble
E01 DAJ0KT (HST controller system)
Contents of
Information in HST controller ROM (non-volatile memory) is abnormal.
trouble
Action of Sets internal adjustment values to defaults.
machine monitor Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on Performance may lower. For example, shift-down feel from 3rd or 4th gear speed may become bad.
machine
Related
information

Carry out troubleshooting according to the following procedure.
1. Change set information of HST controller.
(Example: Change HST selection to B.)
2. Turn starting switch OFF.
Possible causes 3. Wait for at least 30 seconds, then turn starting switch ON again.
and standard 4. At this time, check that set information is reflected.
value in normal 1 Defective HST controller (Example: See if HST selection is kept at B and value is returned
state to default A.)
<Diagnosis>
Set information is not reflected
(Value is returned to default): HST controller is defective.
Set information is reflected
(Value is not returned to default): HST controller is normal.
40-340 22 WA320, 320PZ-6

Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality SEN04193-01
WA320, 320PZ-6 40-340 23

SEN04193-01 Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault
Failure code [DAJ1L4] HST controller main power line: Disconnection/

Ground fault
Action code Failure code HST controller main power line: Disconnection/Ground fault
Trouble
E01 DAJ1L4 (HST controller system)
Contents of
Low voltage was detected in HST controller main power line (battery relay drive voltage system).
trouble
Action of
Starts starting key OFF processing earlier.
machine monitor
Problem that
appears on Machine is not affected in particular.
machine
Related
information

ness (Disconnection in wiring without turning starting switch ON.
Possible causes 1
or defective contact in con- Wiring harness between HST (female) (13) Resis-
and standard nector) Max. 1 z
D09 (female) (1), D10 (female) (1) tance
value in normal
HST (female) Voltage
Between (13) ground 20 30 V
40-340 24 WA320, 320PZ-6

Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault SEN04193-01
WA320, 320PZ-6 40-340 25

SEN04193-01 Failure code [DAJ1L6] HST controller main power line: Hot short
Failure code [DAJ1L6] HST controller main power line: Hot short
Action code Failure code HST controller main power line: Hot short
Trouble
Contents of
Hot short was detected in HST controller main power line (battery relay drive voltage system).
trouble
Continues key OFF processing on assumption that battery relay is turned OFF.
Action of (Turns controller self-holding circuit OFF on assumption that alternator L signal voltage system is
machine monitor turned OFF.)
Displays error next time when starting switch is turned ON.
Problem that
appears on Battery voltage may lower earlier.
machine
Related
After error is detected, it is displayed next time when starting switch is turned ON.
information

Between wiring harness HST (female) (13)
D09 (female) (1), circuit branch end and Voltage Max. 1 V
Hot short (Contact with 5 V, ground
Possible causes 1 24 V circuit) in wiring har- Wiring harness between L02 (female) (2)
and standard ness D10 (female) (2), circuit branch end and Voltage Max. 1 V
value in normal ground
state Wiring harness between E02 (female) (1)
D09 (female) (2), circuit branch end and Voltage Max. 1 V
ground
a Prepare with starting switch OFF, then turn starting switch ON to
OFF and carry out troubleshooting.
40-340 26 WA320, 320PZ-6

Failure code [DAJ1L6] HST controller main power line: Hot short SEN04193-01
WA320, 320PZ-6 40-340 27

SEN04193-01 Failure code [DAJ2KK] Controller solenoid power supply: Low voltage
Failure code [DAJ2KK] Controller solenoid power supply: Low voltage

Action code Failure code Controller solenoid power supply: Low voltage
Trouble
E03 DAJ2KK (HST controller system)
Low voltage was detected in controller solenoid power supply system.
Contents of
(While VIS power supply self-holding relay is ON and battery voltage is above 20 V, solenoid power
trouble
supply voltage below 18 V was detected.)
Action of
Turns all outputs OFF.
machine monitor
Problem that
Machine cannot travel.
appears on
Another failure may not be detected.
machine
Related
If gear is set in neutral and engine is restarted while solenoid voltage is above 19 V, system is reset.
information

(L102) with another Condition does not Relay (L102) is
Defective VIS power supply relay. become normal. normal.
1
holding relay (Internal defect) a Prepare with starting switch OFF, then check unit.
When 24 V is applied Resis-
Max. 1 z
between (1) (2) tance
Possible causes Between terminals of
and standard L102 (male) (3) (5) When no voltage is Resis-
applied between (1) Min. 1 Mz
value in normal tance
(2)
state
2
nector) Max. 1 z
3 Defective HST controller Max. 1 z
fuse FS1 (No. 3) tance
HST Voltage
40-340 28 WA320, 320PZ-6

Failure code [DAJ2KK] Controller solenoid power supply: Low voltage SEN04193-01
WA320, 320PZ-6 40-340 29

SEN04193-01 Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness
Failure code [DAJ2L3] HST controller load power supply holding line:
Hot short in wiring harness
Action code Failure code HST controller load power supply holding line: Hot short in wiring
Trouble harness
Contents of Hot short was detected in HST controller load power supply holding line.
trouble (When output command was ON, output terminal voltage above 5.7 V was detected.)
Action of
Turns output OFF (Control protection function works).
machine monitor
Problem that If starting switch is turned OFF without applying parking brake securely on slope, machine moves
appears on down suddenly.
machine If starting switch is turned OFF while fan is rotating in reverse, peak pressure may occur.
Related
information

Defective VIS power supply (L102) with another Condition does not Relay (L102) is
1
holding relay (Internal defect) relay. become normal. normal.
Possible causes without turning starting switch ON.
and standard
Resis- 200 400
value in normal Between L102 (male) (1) (2)
tance z
state
ness Between wiring harness HST (female) (7)
Voltage Max. 1 V
HST Voltage
40-340 30 WA320, 320PZ-6

Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness SEN04193-01
WA320, 320PZ-6 40-340 31

SEN04193-01 Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault
Failure code [DAJ2L4] HST controller load power supply holding line:
Disconnection/Ground fault
Action code Failure code HST controller load power supply holding line: Disconnection/
Trouble Ground fault
Disconnection or ground fault was detected in load power supply holding line during HST controller
Contents of
final check.
trouble
(During final check, when output command was OFF, voltage below 5.7 V was detected.
Action of
Relay cannot be driven while there is disconnection.
machine monitor
While there is disconnection, when starting switch is turned OFF, parking brake check cannot be
Problem that
controlled and machine moves down.
appears on
If starting switch is turned OFF while disconnection is made or fan is rotating in reverse, peak pres-
machine
sure may occur.
Related
information

and OFF, wait for 30 seconds, and turn it ON again and carry out
troubleshooting.
Defective HST safety relay (L102) with another
1 Condition does not Relay (L102) is
(Internal defect) relay. become normal. normal.
Resis- 200 400
tance z
Possible causes
state ness (Disconnection in wiring Wiring harness between HST (female) (7) Resis-
2 Min. 1 Mz
nector) Wiring harness between L102 (female) (1) Resis-
Min. 1 Mz
fuse FS1 (No.3) tance
cuit) Between wiring harness HST (female) (7) Resis-
Min. 1 Mz
HST Voltage
40-340 32 WA320, 320PZ-6

Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault SEN04193-01
WA320, 320PZ-6 40-340 33

SEN04193-01 Failure code [DAJ5KX] Sensor 5V power supply: Out of output range
Failure code [DAJ5KX] Sensor 5V power supply: Out of output range

Action code Failure code Sensor 5 V power supply: Out of output range
Trouble
E03 DAJ5KX (HST controller system)
Contents of
Sensor 5 V power supply of HST controller is below 4.7 V or above 5.3 V.
trouble
Action of Turns the centralized warning lamp and alarm buzzer ON.
machine monitor Even if cause of failure disappears, system does not reset itself until engine is started again.
Problem that
If this trouble occurs during travel, travel speed may not increase or traction force may be insufficient.
appears on
Once machine stops, maximum travel speed is about 4 km/h.
machine
If there is disconnection or ground fault, [DHH1KX], [DDD7KX] or [DF10KA] is displayed, too.
Related
If there is hot short, [DHH1KY], [DDD7KY] or [DF10KB] is displayed, too.
information
If this failure occurs during travel, [DLT4KX] or [DLT3KX] may be displayed, too.

Defective travel speed con- Travel speed control
Disconnect devices at L54
trol dial, defective speed dial
range selector switch, defec- right in order. If failure
1 code [DAJ5KX] lights Speed range selector
tive resistor, defective travel L03
up (reset is indicated) switch
speed sensor, or defective
HST pressure sensor when a device is dis- Resistor L70
connected, that device Travel speed sensor T09
has trouble in it.
HST pressure sensor T11
and standard Ground fault in wiring har-
value in normal 2 ness (Contact with GND cir- Between wiring harness HST (female) (22)
cuit) L54 (female) (A) or L70 (female) (2), (4) or Resis-
state Min. 1 Mz
T09 (female) (1) or T11 (female) (B) and tance
ground
troubleshooting.
Hot short (Contact with 5 V,
3 24 V circuit) in wiring har- Between wiring harness HST (female) (22)
ness L54 (female) (A) or L70 (female) (2), (4) or
Voltage Max. 1 V
T09 (female) (1) or T11 (female) (B) and
ground
HST Voltage
Between (22) (32) 4.7 5.3 V
40-340 34 WA320, 320PZ-6

Failure code [DAJ5KX] Sensor 5V power supply: Out of output range SEN04193-01
WA320, 320PZ-6 40-340 35

SEN04193-01 Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals
Failure code [DAJ9KQ] HST controller model selection: Disagreement

of model selection signals
Action code Failure code HST controller model selection: Disagreement of model selection
Trouble
E03 DAJ9KQ signals (Machine monitor system)
Contents of
The HST controller model is mistaken for another one.
trouble
Operates on the assumption that the controller model which has been used before occurrence of the
Action of failure code is still used.
Does not display failure codes which may be false detected.
Problem that After HST controller or machine monitor is replaced, if model is not selected, this failure code is dis-
appears on played.
machine Continuing the travel in this condition may damage the HST.
If the model selection is not done correctly after the HST controller or machine monitor is replaced,
Related
this code is displayed.
information

Possible causes Set the model using the adjustment function of the service mode of
Improper machine monitor
and standard 1 the machine monitor (See Special functions of machine monitor
model selection
value in normal (EMMS) in Testing and adjusting)
state HST controller part number Confirm the part number of the HST controller. It must be replaced if
2
error it is not the specified controller.
40-340 36 WA320, 320PZ-6

Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection SEN04193-01
Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection

Action code Failure code HST controller CAN-NET signal: Disconnection
Trouble
E03 DAJRKR (Machine monitor system)
Contents of
Machine monitor cannot get information from HST controller
trouble
Uses CAN information that was sent from HST controller before the occurrence of the error.
Action of
machine monitor
Problem that
The monitor does not display normally
appears on
If HST controller power supply circuit is defective, machine cannot travel in either direction.
machine
Related
information

1
Max. 1 z
state (38) L80 (female) (7), (8) tance
Max. 1 z
ness Wiring harness between HST (female) (28), Resis-
2 Max. 1 z
(Disconnection or defective (38) EC2 (female) (46), (47) tance
contact in connector) Wiring harness between HST (female) (28), Resis-
Max. 1 z
(38) C140 (female) (28), (38) tance
Max. 1 z
Max. 1 z
WA320, 320PZ-6 40-340 37

SEN04193-01 Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection

Min. 1 Mz
Min. 1 Mz
3 ness Min. 1 Mz
(38) EC2 (female) (46), (47) and ground tance
(Contact with ground circuit)
Possible causes Wiring harness between HST (female) (28), Resis-
(38) C140 (female) (28), (38) and ground tance
value in normal
state Min. 1 Mz
Min. 1 Mz
a Carry out troubleshooting in "When HST controller power supply
circuit is defective" described later.
out.)
40-340 38 WA320, 320PZ-6

WA320, 320PZ-6 40-340 39

When HST controller power supply circuit is defective

Broken fuse box FS1 fuse
a If fuse is broken, circuit probably has ground fault etc. (See cause c.)
No. 3
b
or defective contact in con- Wiring harness between fuse box FS1 fuse Resis-
nector) Max. 1 z
No. 3 HST (female) (1) (11). tance
Between wiring harness fuse box FS1 fuse
Resis-
No. 3 HST (female) (1) (11), branch end Min. 1 Mz
tance
and ground
Min. 1 Mz
branch end and ground tance
Min. 1 Mz
D07 (female) (1), T07 (3) and ground tance
Min. 1 Mz
Ground fault in wiring har- D08 (female) (1), T07 (1) and ground tance
c ness (Contact with GND cir- Between wiring harness L104 (female) (5) Resis-
cuit) Min. 1 Mz
R59 (female) (1) and ground tance
Between wiring harness L63 (female) (5), (1) Resis-
Min. 1 Mz
HST (female) (25) and ground tance
Possible causes
Between wiring harness L15 (female) (3),
and standard Resis-
D01 (female) (5) HST (female) (5) and Min. 1 Mz
value in normal tance
ground
state
Min. 1 Mz
HST (female) (34) and ground tance
Between wiring harness L15 (female) (4)
Resis-
L126 (female) (1), HST (female) (15) and Min. 1 Mz
tance
ground
Between (5) (6) 200 400 z
a Prepare with starting switch OFF.
a Test relay unit.
Directional pressure
(1) (2) Resistance
Defective directional pres- selector relay (L101)
d sure selector relay (L101) When 24 V is applied
(Internal short circuit) Max. 1 z
(relay is "ON")
Between (3) (5)
Other than above
Min. 1 Mz
(relay is "OFF")
a Prepare with starting switch OFF, then turn starting switch to
START and carry out troubleshooting.
Replace directional pressure selector relay (L101) with another
relay. If condition becomes normal, directional pressure selector
relay is defective.
40-340 40 WA320, 320PZ-6


Between (1) (2) 200 400 z
a Test relay unit.
Backup alarm/lamp
Defective backup alarm/lamp (1) (2) Resistance
relay (L126)
e relay (L126) (Internal short
circuit) When 24 V is applied
Max. 1 z
(relay is "ON")
Between (3) (5)
Other than above
Min. 1 Mz
(relay is "OFF")
Possible causes
Replace backup alarm/lamp relay (L126) with another relay. If con-
and standard
dition becomes normal, backup alarm/lamp relay is defective.
value in normal
Defective directional pres- without turning starting switch ON.
f sure selector solenoid (Inter-
Resis-
nal short circuit) Between T07 (male) (3) T07 (male) (4) 20 30 z
tance
Defective motor 2 solenoid without turning starting switch ON.
g
(Internal short circuit) Resis-
Between T07 (male) (1) T07 (male) (2) 20 30 z
tance
Defective fan reverse sole- without turning starting switch ON.
h
noid (Internal short circuit) Resis-
Between R59 (male) (1) R59 (male) (2) 35 45 z
tance
i Defective HST controller
HST Voltage
WA320, 320PZ-6 40-340 41

Related circuit diagram (When HST controller power supply circuit is defective)
40-340 42 WA320, 320PZ-6

Failure code [DAJRMA] HST controller: Disagreement in option selection SEN04193-01
Failure code [DAJRMA] HST controller: Disagreement in option

selection
Action code Failure code HST controller: Disagreement in option selection
Trouble
E03 DAJRMA (Machine monitor system)
Contents of Disagreement between the option setting done by the machine monitor and the option recognition by
trouble done the HST controller.
Action of The HST controller follows the option setting being recognized by itself.
Problem that
After HST controller or machine monitor is replaced, if option is not set, this failure code is displayed.
appears on
The option setting does not work normally.
machine
If the option setting is not done correctly after the HST controller or machine monitor is replaced, this
Related
code is displayed.
information

Set the option setting using the option select function of the
Possible causes 1 Defective option setting machine monitor (See Special functions of machine monitor
and standard (EMMS) in Testing and adjusting)
value in normal The machine monitor may be defective. (Since trouble is in system,
state 2 Defective machine monitor
troubleshooting cannot be carried out.)
The HST controller may be defective. (Since trouble is in system,
troubleshooting cannot be carried out.)
WA320, 320PZ-6 40-340 43

SEN04193-01

2009 KOMATSU
All Rights Reserved
40-340 44
SEN04194-01
WA320-6
WA320PZ-6
WA320-6 70001 and up


Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line......................................... 2
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality .................................................... 8
Failure code [DD1NLD] Fan reverse switch signal: Abnormality .................................................................. 10
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short........................................ 12
Failure code [DDB6KB] Parking brake indicator signal: Ground fault........................................................... 14
(intermediate switch): Trouble................................................................................................................ 16
Failure code [DDB6L0] Parking brake reminder signal: Ground fault ........................................................... 18
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short ......................................... 20
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault................................. 22
Failure code [DDD7KY] Travel speed control dial signal: Hot short.............................................................. 24
Failure code [DDE5MA] Emergency steering operation switch: Disconnection............................................ 26
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault .................................................................. 28
Failure code [DDK6KY] FNR lever: Hot short ............................................................................................... 32
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) ............................... 34
WA320, 320PZ-6 40-350 1

SEN04194-01 Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in

signal line
Action code Failure code Engine controller CAN-NET: Disconnection in signal line
Trouble
E03 DB2RKR (HST controller system)
Contents of
Communication via CAN signal line between the HST controller and engine controller is defective.
trouble
Uses CAN information that was sent from engine controller before the occurrence of the error.
Once engine stops, recognized engine speed is fixed to low idle.
Action of
Once engine stops, recognized operating degree of accelerator is fixed to 0%.
controller
Problem that
The monitor does not display normally
appears on
If engine controller power supply circuit is defective, engine stops.
machine
Related
information

Defective CAN end point Between (A) (B) 110 140 z
1
Between (A) (B) 110 140 z
value in normal Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
state (47) HST (female) (28), (38) tance
Max. 1 z
ness Wiring harness between EC2 (female) (46), Resis-
2 Max. 1 z
(Disconnection or defective (47) L29 (female) (3), (8) tance
contact in connector) Wiring harness between EC2 (female) (46), Resis-
Max. 1 z
(47) C140 (female) (28), (38) tance
Max. 1 z
Max. 1 z
40-350 2 WA320, 320PZ-6

Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line SEN04194-01

Min. 1 Mz
(47) HST (female) (28), (38) and ground tance
Min. 1 Mz
3 ness Min. 1 Mz
Possible causes Wiring harness between EC2 (female) (46), Resis-
(47) C140 (female) (28), (38) and ground tance
value in normal
state Min. 1 Mz
Min. 1 Mz
Defective power supply cir- Carry out troubleshooting for "When engine controller power sup-
4
cuit of engine controller ply is defective" described later.
out.)
WA320, 320PZ-6 40-350 3

40-350 4 WA320, 320PZ-6

WA320, 320PZ-6 40-350 5

When engine controller power supply circuit is defective

Defective fuse No. 4 in fuse If fuse box is damaged, circuit probably has ground fault etc.
a
box FS1 or No. 15 in FS2 (See cause c.)
Wiring harness between fuse box FS1, No. 4 Resis-
Max. 1 z
fuse L107 (female) (3), L108 (female) (3) tance
Max. 1 z
Disconnection in wiring har- L108 (female) (5) EC3 (female) (3), (4) tance
ness (Disconnection in wiring Wiring harness between EC3 (female) (1), Resis-
b Max. 1 z
or defective contact in con- (2) ground tance
Max. 1 z
L107 (female) (1), L108 (female) (1) tance
Max. 1 z
L108 (female) (2) EC2 (female) (33) tance
Max. 1 z
EC2 (female) (39) tance
Between wiring harness fuse box FS1, No. 4
Resis-
fuse L107 (female) (3), L108 (female) (3) Min. 1 Mz
tance
Possible causes and ground
and standard Ground fault in wiring har- Between wiring harness L107 (female) (5),
Resis-
value in normal c ness (Contact with GND cir- L108 (female) (5) EC3 (female) (3), (4) and Min. 1 Mz
tance
state cuit) ground
Resis-
L107 (female) (1), L108 (female) (1) and Min. 1 Mz
tance
ground
Min. 1 Mz
EC2 (female) (39) and ground tance
L107, L108 (male) Resistance
Between (1) (2) 200 400 z
a Check relay unit.
Engine controller cut
Defective engine controller (1) (2) Resistance
relay (L107, L108)
d cut relay (L107, L108) (Inter-
nal defect) When 24 V is applied
Max. 1 z
(relay is "ON")
Between (3) (5)
Other than above
Min. 1 Mz
(relay is "OFF")
Replace engine controller cut relay (L107, L108) with another relay.
If condition becomes normal, engine controller cut relay is defective.
40-350 6 WA320, 320PZ-6


Possible causes EC2 Voltage
and standard Between (33) ground Max. 1 V
value in normal e Defective engine controller
state Between (39) ground 20 30 V
EC3 Voltage
Between (1), (2) ground Max. 1 V
Related circuit diagram (When engine controller power supply circuit is defective)
WA320, 320PZ-6 40-350 7

SEN04194-01 Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality
Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality

Action code Failure code Fan automatic reverse switch signal: Abnormality
Trouble
E01 DD1NL4 (HST controller system)
Contents of Because of hot short in fan automatic reverse switch system, fan automatic reverse switch input and
trouble fan manual reverse switch input were sensed simultaneously.
Action of
Turns automatic reverse switch function OFF.
controller
Problem that
After error is detected, fan does not reverse.
appears on
Automatic reverse switch LED lamp keeps lighting.
machine
Input state from fan automatic reverse switch can be checked with monitoring function
Related
(Code: HST 93400 FAN REVERSE SW) (Code: MONITOR PANEL 40901 D-IN-9).
information
Method of reproducing failure code: Turn starting switch ON and fan manual reverse switch ON.

Defective fan automatic Fan automatic reverse
1 reverse switch (Internal short L69 (male) Resistance
switch
circuit)
ON Max. 1 z
Between (3), (4) (5)
OFF Min. 1 Mz
Possible causes a Prepare with starting switch OFF, then turn starting switch ON
and standard and carry out troubleshooting.
value in normal Hot short in wiring harness (Carry out troubleshooting with automatic reverse switch OFF)
2
state (Contact with 5 V, 24 V circuit)
Wiring harness between L25 (female) (14)
Voltage Max. 1 V
L69 (female) (3), (4) and ground
Fan automatic reverse
3 Defective machine monitor L25 (male) Voltage
switch
Between (14) and ON 20 30 V
ground OFF Max. 1 V
40-350 8 WA320, 320PZ-6

Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality SEN04194-01
WA320, 320PZ-6 40-350 9

SEN04194-01 Failure code [DD1NLD] Fan reverse switch signal: Abnormality
Failure code [DD1NLD] Fan reverse switch signal: Abnormality

Action code Failure code Fan reverse switch signal: Abnormality
Trouble
E01 DD1NLD (HST controller system)
Contents of Since the fan manual reverse switch system is shorted with the power source, the fan manual
trouble reverse switch remains at ON position. (Continuation for 30 seconds determines fault)
Action of
None in particular.
controller
Problem that
appears on Fan remains in the reverse rotation.
machine
The input state (ON/OFF) from the fan manual reverse switch can be checked with the monitoring function
Related (Code: HST 93400 FAN REVERSE SW).
information (Code: MONITOR PANEL 40900 D-IN-1).

Defective fan reverse switch Fan manual reverse
1 L69 (male) Resistance
(Internal short circuit) switch
Between ON Max. 1 z
(5) (1), (16) OFF Min. 1 Mz
Possible causes
and standard
Hot short in wiring harness and carry out troubleshooting.
value in normal 2
state (Contact with 5 V, 24V circuit) Wiring harness between L25 (female) (10)
Voltage Max. 1 V
L69 (female) (1), (6) and ground
Fan manual reverse
3 Defective machine monitor L25 (male) Voltage
switch
Between (10) and ON 20 30 V
ground OFF Max. 1 V
40-350 10 WA320, 320PZ-6

Failure code [DD1NLD] Fan reverse switch signal: Abnormality SEN04194-01
WA320, 320PZ-6 40-350 11

SEN04194-01 Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/

Hot short
Action code Failure code Parking brake reminder signal: Disconnection/Hot short
Trouble
E01 DDB6KA (HST controller system)
HST controller detected disagreement with parking brake reminder signal from machine monitor.
Contents of (While parking brake reminder signal of machine monitor was input (closed), there was not parking
trouble brake reminder signal of HST controller (open).
While there was not input signal (open), signal was input to parking brake indicator signal (closed).
Action of
None in particular.
controller
Problem that
If starting switch is turned OFF without applying parking brake securely on slope, machine moves
appears on
down suddenly.
machine
Operation of parking brake can be checked with monitoring function.
[Parking brake reminder signal] (Recognition by machine monitor)
(Monitoring code: MONITOR PANEL 40903 D-IN-28 and 40904 D-IN-35)
Related
[Parking brake indicator signal] (Recognition by machine monitor)
information
[Parking brake signal: reminder (A)/indicator (B)] (HST controller recognition)
(Monitoring code: HST 99100 PARKING A/B)

Defective diode (See Testing and adjusting, Test procedure for diode.)
1
(Internal defect)
Between D02 (male) (6) (2) Continuity is secured
2
nector) Max. 1 z
Ground fault in wiring har- (Test with parking brake applied.)
3 ness (Contact with GND cir- Between wiring harness HST (female) (16) Resis- Min.
Possible causes cuit) D02 (female) (5) and ground tance 1 Mz
and standard Between wiring harness L27 (female) (2), Resis- Min.
value in normal (14) D02 (female) (8) and ground tance 1 Mz
Hot short (Contact with 5 V, (Test with parking brake released.)
4
24V circuit) in wiring harness
Voltage Max. 1 V
D02 (female) (6) and ground
troubleshooting.
5 Defective HST controller (Test with parking brake applied.)
HST Voltage
a Prepare with starting switch OFF, turn starting switch ON and
carry out troubleshooting.
6 Defective machine monitor (Test with parking brake applied.)
L27 Voltage
Between (2) (14) ground 20 30 V
40-350 12 WA320, 320PZ-6

Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short SEN04194-01
WA320, 320PZ-6 40-350 13

SEN04194-01 Failure code [DDB6KB] Parking brake indicator signal: Ground fault
Failure code [DDB6KB] Parking brake indicator signal: Ground fault

Action code Failure code Parking brake indicator signal: Ground fault
Trouble
E01 DDB6KB (HST controller system)
Contents of While parking brake indicator signal of machine monitor was not input (open), there was input signal
trouble (switch B was closed).
Action of
None in particular.
controller
Problem that
Since machine can travel forward and reverse while parking brake is applied, parking brake may be
appears on
damaged (Alarm buzzer sounds in this case, however).
machine
Related
information

Defective diode without turning starting switch ON.
1 (See Testing and adjusting, Test procedure for diode.)
(Internal defect)
2
or defective contact in con- Wiring harness between L27 (female) (1), (6) Resis-
nector) Max. 1 z
Possible causes Ground fault in wiring har- without turning starting switch ON.
and standard 3 ness (Contact with GND cir- (Test with parking brake applied.)
value in normal cuit) Between wiring harness HST (female) (16) Resis- Min.
state D02 (female) (5) and ground tance 1 Mz
troubleshooting.
HST Voltage
5 Defective machine monitor (Test with parking brake released.)
L27 Voltage
Between (1) (6) ground Max. 1 V
40-350 14 WA320, 320PZ-6

Failure code [DDB6KB] Parking brake indicator signal: Ground fault SEN04194-01
WA320, 320PZ-6 40-350 15

SEN04194-01 (intermediate switch): Trouble
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking

brake reminder switch (intermediate switch): Trouble
Action code Failure code Parking brake switch (bottom switch) or parking brake reminder
Trouble
E03 DDB6KZ switch (intermediate switch): Trouble (Machine monitor system)
Contents of Parking brake indicator signal was closed and opening of parking brake reminder signal was
trouble detected.
machine monitor Turns parking brake indicator and parking brake remind caution lamp ON.
Problem that While parking brake is in intermediate position, parking brake reminder caution lamp does not light.
appears on While parking brake is in intermediate position, parking brake reminder buzzer does not sound.
machine While parking brake is in intermediate position, centralized warning lamp does not light.
Input state (ON/OFF) of parking brake indicator signal and reminder signal can be checked with
Related monitoring function.
information (Monitoring code: MONITOR PANEL 40903 D-IN-26, 28)
(Monitoring code: MONITOR PANEL 40904 D-IN-35, 36)

Defective diode (See Testing and adjusting, Test procedure for diode.)
1
(Internal defect)
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness (Disconnection in wiring (Test with parking brake released.)
2
value in normal or defective contact in con-
state nector) Max. 1 z
(14) L53 (female) (2) tance
3 ness (Contact with GND cir- (Test with parking brake applied.)
cuit) Between wiring harness L27 (female) (1), (6) Resis- Min.
D02 (female) (7) and ground tance 1 Mz
If causes 1 3 are not detected, machine monitor may be defective.
40-350 16 WA320, 320PZ-6

(intermediate switch): Trouble SEN04194-01
WA320, 320PZ-6 40-350 17

SEN04194-01 Failure code [DDB6L0] Parking brake reminder signal: Ground fault
Failure code [DDB6L0] Parking brake reminder signal: Ground fault

Action code Failure code Parking brake reminder signal: Ground fault
Trouble
E01 DDB6L0 (HST controller system)
Contents of While parking brake reminder signal operation signal of machine monitor was not input (open), park-
trouble ing brake reminder signal operation signal of HST controller was input (closed).
Action of When engine is stopped while parking brake is not applied securely, move-down prevention is not
controller controlled.
Problem that
If starting switch is turned OFF without applying parking brake securely on slope, machine moves
appears on
down suddenly.
machine
Related
information

(Internal defect)
ness (Disconnection in wiring (Test with parking brake released.)
2
or defective contact in con-
nector) Max. 1 z
(14) L53 (female) (2) tance
Possible causes Ground fault in wiring har- without turning starting switch ON.
and standard 3 ness (Contact with GND cir- (Test with parking brake applied.)
value in normal cuit) Between wiring harness HST (female) (6) Resis- Min.
state
D02 (female) (6) and ground tance 1 Mz
HST Voltage
L27 Voltage
Between (1) (6) ground Max. 1 V
40-350 18 WA320, 320PZ-6

Failure code [DDB6L0] Parking brake reminder signal: Ground fault SEN04194-01
WA320, 320PZ-6 40-350 19

SEN04194-01 Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/

Hot short
Action code Failure code Parking brake indicator signal: Disconnection/Hot short
Trouble
E03 DDB6L4 (HST controller system)
Contents of HST controller detected disagreement with parking brake indicator signal from machine monitor.
trouble (While signal was input to machine monitor (closed), signal was not input to HST controller (open).
Action of Stops neutralizer (parking brake drag prevention function).
controller If error is detected during forward or reverse travel, gear is set in neutral.
Once FNR selector lever or switch is set to N, normal control is started again.
If error is detected while FNR selector lever or switch is in F or R, machine cannot start until gear is
Problem that
returned to neutral.
appears on
Since machine can travel forward and reverse while parking brake is applied, parking brake may be
machine
damaged (Caution buzzer sounds in this case, however).
Related
information

(Internal defect)
2
nector) Max. 1 z
3 ness (Contact with GND cir- (Test with parking brake applied.)
cuit) Between wiring harness L27 (female) (1), (6) Resis- Min.
Possible causes
and standard D02 (female) (7) and ground tance 1 Mz
value in normal a Prepare with starting switch OFF, then turn starting switch ON
state Hot short (Contact with 5 V, and carry out troubleshooting.
4
24V circuit) in wiring harness Between wiring harness HST (female) (16)
Voltage Max. 1 V
D02 (female) (5) and ground
5 Defective HST controller (Test with parking brake released.)
HST Voltage
L27 Voltage
Between (1) (6) ground 20 30 V
40-350 20 WA320, 320PZ-6

Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short SEN04194-01
WA320, 320PZ-6 40-350 21

SEN04194-01 Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/

Ground fault
Action code Failure code Travel speed control dial signal: Disconnection/Ground fault
Trouble
E01 DDD7KX (HST controller system)
Contents of
Travel speed control dial signal voltage lowered below 0.3 V.
trouble
Action of Continue controls on assumption that travel speed control dial is set to minimum speed side.
controller Even if trouble disappears, system does not reset itself until starting switch is turned OFF.
Problem that
Travel speed cannot be adjusted with travel speed control dial.
appears on
If speed range selector switch is set in 1st, travel speed is set to about 4 km/h.
machine
Related
If failure code [DAJ5KX] is also displayed, carry out troubleshooting for it first.
information

4.7 5.3
Between L54 (female) (1) (3) Voltage
Defective travel speed con- V
1
trol dial (Internal defect) Between L54 (female) (2) (3) (Max. speed 0.3 0.9
Voltage
side of dial) V
Between L54 (female) (2) (3) (Min. speed 4.1 4.7
Voltage
side of dial) V
ness (Disconnection in wiring Wiring harness between HST (female) (23) Resis-
2 Max. 1 z
Possible causes nector) Wiring harness between HST (female) (22) Resis-
value in normal L54 (female) (1) tance
cuit) Between wiring harness HST (female) (23) Resis- Min.
L54 (female) (2) and ground tance 1 Mz
HST (female) Resistance
Between (32) ground Max. 1 z
4 Defective HST controller a Prepare with starting switch OFF, then turn starting switch ON
Between (22) ground 4.7 5.3 V
40-350 22 WA320, 320PZ-6

Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault SEN04194-01
WA320, 320PZ-6 40-350 23

SEN04194-01 Failure code [DDD7KY] Travel speed control dial signal: Hot short
Failure code [DDD7KY] Travel speed control dial signal: Hot short
Action code Failure code Travel speed control dial signal: Hot short
Trouble
E01 DDD7KY (HST controller system)
Contents of
Travel speed control dial signal voltage exceeded 4.7 V.
trouble
Action of
None in particular.
controller
Problem that
Travel speed cannot be adjusted with travel speed control dial.
appears on
If speed range selector switch is set in 1st, travel speed is set to about 4 km/h.
machine
Related
If failure code [DAJ5KX] is also displayed, carry out troubleshooting for it first.
information

4.7 5.3
Between L54 (female) (1) (3) Voltage
Defective travel speed con- V
1
trol dial (Internal defect) Between L54 (female) (2) (3) (Max. speed 0.3 0.9
Voltage
side of dial) V
Between L54 (female) (2) (3) (Min. speed 4.1 4.7
Voltage
side of dial) V
2
Possible causes nector) Max. 1 z
and standard
state Hot short (Contact with5 V, and carry out troubleshooting.
3
Voltage Max. 1 V
HST (female) Resistance
Between (32) ground Max. 1 z
4 Defective HST controller a Prepare with starting switch OFF, then turn starting switch ON
40-350 24 WA320, 320PZ-6

Failure code [DDD7KY] Travel speed control dial signal: Hot short SEN04194-01
WA320, 320PZ-6 40-350 25

SEN04194-01 Failure code [DDE5MA] Emergency steering operation switch: Disconnection
Failure code [DDE5MA] Emergency steering operation switch:

Disconnection
Action code Failure code Emergency steering operation switch: Disconnection
Trouble
E01 DDE5MA (Machine monitor system)
Contents of While engine was stopped, steering pump oil pressure was sensed because of disconnection in
trouble steering oil pressure reduction switch (emergency steering operation switch) system.
Action of
None in particular.
machine monitor
Problem that
appears on When steering oil pressure reduces, steering oil pressure caution lamp does not light.
machine
This code is applied to only emergency steering specification model and is not turned ON if not
selected as option with machine monitor.
Related
Input state (ON/OFF) from steering oil pressure reduction switch can be checked with monitoring
information
function.
(Monitoring code: MONITOR PANEL 40904 D-IN-39)

and start engine and carry out troubleshooting in each case.
F11 (male) Steering oil pressure Resistance
Defective steering oil pres- Oil pressure reduction
Max. 1 z
1 sure reduction switch (Inter- (Engine is stopped)
nal defect) Between (1) (2)
Oil pressure normal
Min. 1 Mz
(Engine is running)
Between (1), (2)
Normally Min. 1 Mz
ground
Possible causes
and standard
value in normal
state ness (Disconnection in wiring Wiring harness between L27 (female) (16) Resis-
2 Max. 1 z
or defective contact in con- F11 (female) (1) tance
nector) Resis-
Between F11 (female) (2) ground Max. 1 z
tance
and start engine and carry out troubleshooting in each case.
L27 Steering oil pressure Voltage
3 Defective machine monitor Oil pressure reduction
Max. 1 V
Between (16) (Engine is stopped)
ground Oil pressure normal
20 30 V
(Engine is running)
40-350 26 WA320, 320PZ-6

Failure code [DDE5MA] Emergency steering operation switch: Disconnection SEN04194-01
WA320, 320PZ-6 40-350 27

SEN04194-01 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault

Action code Failure code FNR lever: Disconnection/Ground fault
Trouble
E03 DDK6KA (HST controller system)
Contents of No signal of FNR (directional) lever is input because of disconnection or ground fault in FNR (direc-
trouble tional) lever switch signal system.
If directional selector switch is not installed, gear is set in neutral.
If directional selector switch actuation switch is turned OFF, gear is set in neutral (Only machine with
directional selector switch actuation switch).
Action of If directional selector switch actuation switch is turned ON, FNR (directional) lever switch controls on
controller assumption that gear is in neutral (Only machine with directional selector switch actuation switch).
Even if trouble disappears, system does not reset itself until FNR (directional) lever is set in N (Neu-
tral).
Machine cannot be driven with FNR (directional) lever.
Problem that
Machine can be driven with directional selector switch (only machine with directional selector switch
appears on
actuation switch).
machine
Gear shift lever position lamp goes off.
The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related
function (Code: HST 40977 D-IN-0, D-IN-1 or D-IN-2).
information
Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever

1
box (FS1) (See cause 5.)
FNR (directional)
L15 Voltage
lever
Between (1) and
Constant 20 30 V
Defective FNR (directional) ground
2 lever switch (Internal discon- Between (3) and N (Neutral) 20 30 V
nection or short circuit) ground Other than above Max. 1 V
Possible causes F (Forward) 20 30 V
Between (2) and
and standard
ground Other than above Max. 1 V
value in normal
state Between (4) and R (Reverse) 20 30 V
supply holding relay normal defective
3
holding relay (Internal defect) relay become normal normal
Resis- 200
tance 400 z
40-350 28 WA320, 320PZ-6

Failure code [DDK6KA] FNR lever: Disconnection/Ground fault SEN04194-01

Wiring harness between fuse No. 3 of fuse Resis-
Max. 1 z
box (FS1) L102 (female) (5) and ground tance
Max. 1 z
ness L15 (female) (1) tance
4
(Disconnection or defective Wiring harness between HST (female) (15) Resis-
Wiring harness between HST (female) (5) Resis-
Max. 1 z
Max. 1 z
Min. 1 Mz
Possible causes Wiring harness between L102 (female) (3)

Resis-
and standard L15 (female) (1), circuit branch end and Min. 1 Mz
tance
value in normal Grounding fault in wiring har- ground
state 5 ness Wiring harness between HST (female) (15)
(Contact with ground circuit) L15 (female) (4), L126 (female) (13) and Resis-
Min. 1 Mz
tance
ground
Wiring harness between HST (female) (5)
Resis-
L15 (female) (3), D01 (female) (5) and Min. 1 Mz
tance
ground
Min. 1 Mz
FNR (directional)
HST Voltage
lever
Between (5) and N (Neutral) 20 30 V
6 Defective HST controller ground Other than above Max. 1 V
Between (34) and F (Forward) 20 30 V
Between (15) and R (Reverse) 20 30 V
WA320, 320PZ-6 40-350 29

SEN04194-01 Failure code [DDK6KA] FNR lever: Disconnection/Ground fault
40-350 30 WA320, 320PZ-6

Failure code [DDK6KA] FNR lever: Disconnection/Ground fault SEN04194-01
WA320, 320PZ-6 40-350 31

SEN04194-01 Failure code [DDK6KY] FNR lever: Hot short
Failure code [DDK6KY] FNR lever: Hot short

Action code Failure code FNR lever: Hot short
Trouble
E03 DDK6KY (HST controller system)
Contents of Multiple FNR (directional) lever signals are input because of hot short in FNR (directional) lever
trouble switch signal system.
Sets gear in neutral.
Action of If directional selector switch actuation switch is turned ON, machine is driven according to directional
controller selector switch setting (only machine with directional selector switch actuation switch).
Even if trouble disappears, system does not reset itself until FNR (directional) lever is set in N (Neu-
tral).
Operator cannot travel machine at position other than position having hot short with FNR (directional)
Problem that lever switch. (Example: When directional lever F system has hot short, if lever is set in F, trouble is
appears on reset and machine can travel forward.)
machine Multiple gear shift lever position lamp lights.
Machine can be driven with directional selector switch (only machine with directional selector switch).
The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
Related
function (Code: HST 40977 D-IN-0, D-IN-1 or D-IN-2).
information
Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever

FNR (directional)
L15 Voltage
lever
Between (1) and
Constant 20 30 V
Defective FNR (directional) ground
1 lever switch (Internal short Between (3) and F (Forward) 20 30 V
circuit) ground Other than above Max. 1 V
and standard
value in normal Wiring harness between HST (female) (15)
Hot short in wiring harness Voltage Max. 1 V
state L15 (female) (4) and ground
2 (Contact with 5 V, 24V cir-
cuit) Wiring harness between HST (female) (5)
Voltage Max. 1 V
Wiring harness between HST (female) (34)
Voltage Max. 1 V
FNR (directional)
HST Voltage
lever
Between (34) and F (Forward) 20 30 V
40-350 32 WA320, 320PZ-6

Failure code [DDK6KY] FNR lever: Hot short SEN04194-01
WA320, 320PZ-6 40-350 33

SEN04194-01 Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)
Failure code [DDS5L6] Steering: Low oil pressure (Operation of

emergency steering)
Action code Failure code Steering: Low oil pressure (Operation of emergency steering)
Trouble
E03 DDS5L6 (Machine monitor system)
Contents of
While engine was running, steering oil pressure sensor signal was closed.
trouble
machine monitor Turns steering oil pressure warning lamp ON.
Problem that
appears on Steering system does not work except when HST circuit oil pressure is high during travel etc.
machine
Related
This code is applied to only machine with emergency steering (optional).
information

System is normal.
1 Low steering oil pressure
a Carry out troubleshooting for hydraulic and mechanical systems.
F11 (male) Steering oil pressure Resistance
When oil pressure is
Defective steering oil pres- low
2 sure sensor (switch) (Internal Max. 1 z
(While engine is
defect) stopped)
Between (1) (2)
normal
Possible causes Min. 1 Mz
(While engine is
and standard running)
value in normal
cuit) Between wiring harness L27 (female) (16) Resis- Min.
F11 (female) (1) and ground tance 1 Mz
troubleshooting.
L27 Steering oil pressure Voltage
4 Defective machine monitor abnormal (low) (below Max. 1 V
Between (16) 0.5 MPa {5.1 kg/cm2})
ground When oil pressure is
normal (above 0.9 20 30 V
MPa {9.2 kg/cm2})
40-350 34 WA320, 320PZ-6

Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) SEN04194-01
WA320, 320PZ-6 40-350 35

SEN04194-01

2009 KOMATSU
All Rights Reserved
40-350 36
SEN04195-01
WA320-6
WA320PZ-6
WA320-6 70001 and up


Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault.............................. 2
Failure code [DF10KB] Travel speed range selector switch: Hot short........................................................... 6
Failure code [DGH1KX] HST oil temperature sensor: Ground fault................................................................ 8
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault ............................................................. 9
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short ......................................... 10
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault............................................ 12
Failure code [DHH1KY] HST oil pressure sensor: Hot short ........................................................................ 14
Failure code [DHTCL6] HST filter clogging sensor: Functional defect.......................................................... 16
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short ............................................................. 18
Failure code [DLT3KX] Travel speed sensor B: Abnormality ........................................................................ 20
Failure code [DLT4KX] Travel speed sensor A: Abnormality ........................................................................ 24
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality ................................................................. 26
Failure code [DV00KY] Alarm buzzer: Hot short........................................................................................... 28
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault ....................................................... 30
Failure code [DW26KY] Motor 2 solenoid: Hot short .................................................................................... 32
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short .................................................................. 34
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault...................................... 36
WA320, 320PZ-6 40-360 1

SEN04195-01 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault
Failure code [DF10KA] Travel speed range selector switch:

Disconnection/Ground fault
Action code Failure code Travel speed range selector switch: Disconnection/Ground fault
Trouble
E01 DF10KA (HST controller system)
Contents of Travel speed range selector switch signal is not input because of disconnection or ground fault in
trouble travel speed range selector switch input signal system.
Action of Fixes gear to speed range before error occurrence.
controller If trouble disappears, system resets itself.
Once starting switch is turned OFF, gear speed is assumed to be 4th for control, regardless of
Problem that selected speed range.
appears on Gear is not set in selected speed range.
machine Indicator displays range before error occurrence.
(Once starting switch is turned OFF, 4th gear is displayed)
Related
Method of reproducing failure code: Turn starting switch ON + Operate speed range selector switch.
information

L03 (female) Switch position Resistance
2nd Max. 1 z
Between (1) (2)
Other than above Min. 1 Mz
1st Min. 1 Mz
2nd Min. 1 Mz
Between (1) (3)
3rd Max. 1 z
Defective travel speed range
1 selector switch (Internal 4th Max. 1 z
defect) 4th Max. 1 z
Between (1) (4)
Possible causes Other than above Min. 1 Mz
and standard
Between (2) (3) (Anytime) Min. 1 Mz
value in normal
state Between (2) (4) (Anytime) Min. 1 Mz
1st Max. 1 z
2nd Min. 1 Mz
Between (3) (4)
3rd Min. 1 Mz
4th Max. 1 z
2 selector resistor (Internal Between (1) (5) 100 z 1%
defect) Between (2) (6) 220 z 1%
Between (3) (7) 330 z 1%
Between (4) (8) 470 z 1%
40-360 2 WA320, 320PZ-6

Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault SEN04195-01

Max. 1 z
Max. 1 z
Disconnection in wiring har- L03 (female) (3), L70 (female) (5), (3) tance
ness (Disconnection in wiring Wiring harness between L03 (female) (1) Resis-
3 Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
L70 (female) (2) (4) tance
and standard Between wiring harness HST (female) (32) Resis-
value in normal Min. 1 Mz
state
Resis-
Ground fault in wiring har- L03 (female) (3), L70 (female) (5), (3) and Min. 1 Mz
tance
4 ness (Contact with GND cir- ground
Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
HST Switch position Voltage
5 Defective HST controller 1st 1.9 2.3 V
2nd 2.4 2.7 V
Between (39) (32)
3rd 2.9 3.2 V
4th 3.3 3.7 V
WA320, 320PZ-6 40-360 3

SEN04195-01 Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault
40-360 4 WA320, 320PZ-6

Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault SEN04195-01
WA320, 320PZ-6 40-360 5

SEN04195-01 Failure code [DF10KB] Travel speed range selector switch: Hot short
Failure code [DF10KB] Travel speed range selector switch: Hot short
Action code Failure code Travel speed range selector switch: Hot short
Trouble
E01 DF10KB (HST controller system)
Contents of Multiple travel speed range selector switch signal is input because of hot short in travel speed range
trouble selector switch input signal system.
Action of Fixes gear to speed range before error occurrence.
controller If trouble disappears, system resets itself.
Once starting switch is turned OFF, gear speed is assumed to be 4th for control, regardless of
Problem that selected speed range.
appears on Gear is not set in selected speed range.
machine Indicator displays range before error occurrence.
(Once starting switch is turned OFF, 4th gear is displayed)
Related
Method of reproducing failure code: Turn starting switch ON + Operate speed range selector switch.
information

L03 (female) Switch position Resistance
2nd Max. 1 z
Between (1) (2)
1st Min. 1 Mz
2nd Min. 1 Mz
Between (1) (3)
3rd Max. 1 z
1 selector switch (Internal 4th Max. 1 z
defect) 4th Max. 1 z
Between (1) (4)
1st Max. 1 z
Possible causes 2nd Min. 1 Mz
and standard Between (3) (4)
value in normal 3rd Min. 1 Mz
state 4th Max. 1 z
2 selector resistor (Internal Between (1) (5) 100 z 1%
defect) Between (2) (6) 220 z 1%
Between (3) (7) 330 z 1%
Between (4) (8) 470 z 1%
Voltage Max. 1 V
Hot short (Contact with 5V,
3
L03 (female) (3), L70 (female) (5), (3) and Voltage Max. 1 V
ground
Voltage Max. 1 V
40-360 6 WA320, 320PZ-6

Failure code [DF10KB] Travel speed range selector switch: Hot short SEN04195-01

Voltage Max. 1 V
Hot short (Contact with 24V
3 circuit) in wiring harness Voltage Max. 1 V
Possible causes
and standard Wiring harness between HST (female) (22)
Voltage Max. 1 V
value in normal L70 (female) (2) (4) and ground
state HST Switch position Voltage
1st 1.9 2.3 V
4 Defective HST controller 2nd 2.4 2.7 V
Between (39) (32)
3rd 2.9 3.2 V
4th 3.3 3.7 V
WA320, 320PZ-6 40-360 7

SEN04195-01 Failure code [DGH1KX] HST oil temperature sensor: Ground fault
Failure code [DGH1KX] HST oil temperature sensor: Ground fault

Action code Failure code HST oil temperature sensor: Ground fault
Trouble
E01 DGH1KX (Machine monitor system)
Contents of HST oil temperature higher than 150C was detected. (Ground fault in HST oil temperature signal
trouble circuit was detected.)
Action of
HST oil overheat is not detected.
machine monitor
Problem that
appears on HST oil temperature gauge indicates maximum.
machine
Input state from HST oil temperature sensor can be checked with monitoring function.
Related
(Monitoring code: MONITOR PANEL 04408 HST OIL TEMP (C)
information
(Monitoring code: MONITOR PANEL 04409 HST OIL TEMP (V)

T10 (male) HST oil temperature Resistance
Defective HST oil tempera-
1 At 25C 35 50 kz
ture sensor (Internal defect) Between (1) (2)
At 100C 3.1 4.5 kz
Between (1) (2) and
Possible causes (Anytime) Min. 1 Mz
ground
and standard
state 2 ness (Contact with GND cir-
Min. 1 Mz
T10 (female) (1) and ground tance
3 Defective machine monitor L28 (female) HST oil temperature Voltage
At 25C 4.4 4.6 V
Between (2) ground
At 100C 2.1 2.3 V
40-360 8 WA320, 320PZ-6

Failure code [DGR2KB] Brake oil temperature sensor: Ground fault SEN04195-01
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault

Action code Failure code Brake oil temperature sensor: Ground fault
Trouble
E01 DGR2KB (Machine monitor system)
Contents of Front brake oil temperature above 150C was detected.
trouble (Ground fault was detected in front brake oil temperature signal circuit.)
Action of
Brake oil overheat is not detected.
machine monitor
Problem that
Brake oil temperature gauge indicates upper limit.
appears on
Brake performance lowers (while system is normal).
machine
Input state from front brake oil temperature sensor can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL 30201 F BRAKE OIL (C)
information (Monitoring code: MONITOR PANEL 30204 F BRAKE OIL (V)
System resets itself after brake oil temperature reduces below 130C.

Front brake overheat
1 Check for cause of overheat directly.
(When system is normal)
Defective front brake (axle) F14 (male) Brake oil temperature Resistance
2 oil temperature sensor (Inter- At 25C 35 50 kz
nal defect) Between (1) (2)
Possible causes At 100C 3.1 4.5 kz
and standard Between (1) (2) and
value in normal (Anytime) Min. 1 Mz
ground
state
Ground fault in wiring har-
Between wiring harness F14 (female) (1) Resis-
3 ness (Contact with GND cir- Min. 1 Mz
cuit)
4 Defective machine monitor L25, L28 Brake oil temperature Voltage
Between L28 (7) At 25C 4.4 4.6 V
L25 (9) At 100C 2.1 2.3 V
WA320, 320PZ-6 40-360 9

SEN04195-01 Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/

Hot short
Action code Failure code Brake oil temperature sensor: Disconnection/Hot short
Trouble
E01 DGR2KZ (Machine monitor system)
Disconnection or hot short was detected in front brake oil temperature signal circuit.
Contents of
Reference: Detection is made by sudden change of brake oil temperature or by logic of comparison
trouble
with HST oil temperature.
Action of
None in particular.
machine monitor
Problem that
Brake oil temperature gauge indicates lower limit.
appears on
Brake may be broken and brake may not work because of brake oil temperature error.
machine
Input state from front brake oil temperature sensor can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL 30201 F BRAKE OIL (C)
information (Monitoring code: MONITOR PANEL 30204 F BRAKE OIL (V)
System resets itself after brake oil temperature increases above 25C.

Defective front brake (axle)
1 oil temperature sensor (Inter- F14 (male) Brake oil temperature Resistance
nal defect) At 25C 35 50 kz
Between (1) (2)
At 100C 3.1 4.5 kz
ness (Disconnection in wiring Wiring harness between F14 (female) (1) Resis-
2 Max. 1 z
Possible causes nector) Wiring harness between F14 (female) (2) Resis-
value in normal
Hot short (Contact with 5 V, Between wiring harness F14 (female) (1)
3 Voltage Max. 1 V
24V circuit) in wiring harness L28 (female) (7) and ground
Between wiring harness F14 (female) (2)
Voltage Max. 1 V
4 Defective machine monitor L25, L28 Brake oil temperature Voltage
Between L28 (7) At 25C 4.4 4.6 V
L25 (9) At 100C 2.1 2.3 V
40-360 10 WA320, 320PZ-6

Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short SEN04195-01
WA320, 320PZ-6 40-360 11

SEN04195-01 Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground

fault
Action code Failure code HST oil pressure sensor: Disconnection/Ground fault
Trouble
E03 DHH1KX (HST controller system)
Contents of HST oil pressure sensor signal is not input because of disconnection or ground fault in HST oil pres-
trouble sure sensor system (Input voltage is below 0.3 V)
If trouble occurs during travel, control value (output) before trouble occurrence is held.
Action of
Once machine stops, gear is assumed to be in 1st for control.
controller
Problem that
Once machine stops, gear is set in 1st. (Travel speed can be controlled with travel speed control
appears on
dial, however.)
machine
If [DAJ5KX] is displayed, carry out troubleshooting for it first.
Related Input state from HST oil pressure sensor can be checked with monitoring function.
information (Monitoring code: HST 32600 HST PRESS (MPa))
(Monitoring code: HST 32601 HST PRESS (V))

a Prepare with starting switch OFF, then turn starting twitch ON and
Defective HST oil pressure T11 Voltage
1
sensor (Internal defect)
Between (C) (A) 0.5 4.5 V
Between (B) (A) 46V
Max. 1 z
ness (Disconnection in wiring T11 (female) (C) tance
2
Possible causes nector) Max. 1 z
T11 (female) (A) tance
and standard
value in normal Max. 1 z
state T11 (female) (B) tance
Between wiring harness HST (female) (33) Resis- Min.
T11 (female) (C) and ground tance 1 Mz
cuit)
Between wiring harness HST (female) (22) Resis- Min.
T11 (female) (B) and ground tance 1 Mz
troubleshooting.
4 Defective HST controller HST Voltage
Between (33) (32) 0.5 4.5 V
Between (22) (32) 46V
40-360 12 WA320, 320PZ-6

Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault SEN04195-01
WA320, 320PZ-6 40-360 13

SEN04195-01 Failure code [DHH1KY] HST oil pressure sensor: Hot short
Failure code [DHH1KY] HST oil pressure sensor: Hot short

Action code Failure code HST oil pressure sensor: Hot short
Trouble
E03 DHH1KY (HST controller system)
Contents of Abnormal HST oil pressure sensor signal was input because of hot short in HST oil pressure sensor
trouble system (Input voltage was above 4.7 V).
If trouble occurs during travel, control value (output) before trouble occurrence is held.
Action of
Once machine stops, gear is assumed to be in 1st for control.
controller
Problem that
Once machine stops, gear is set in 1st. (Travel speed can be controlled with travel speed control
appears on
dial, however.)
machine
If [DAJ5KX] is displayed, carry out troubleshooting for it first.
Related Input state from HST oil pressure sensor can be checked with monitoring function.
information (Monitoring code: HST 32600 HST PRESS (MPa))
(Monitoring code: HST 32601 HST PRESS (V))

troubleshooting.
Defective HST oil pressure T11 Voltage
1
sensor (Internal defect)
Between (C) (A) 0.5 4.5 V
Between (B) (A) 46V
Possible causes
and standard
value in normal 2
state 24V circuit) in wiring harness Between wiring harness HST (female) (33)
Voltage Max. 1 V
T11 (female) (C) and ground
troubleshooting.
Between (33) (32) 0.5 4.5 V
Between (22) (32) 46V
40-360 14 WA320, 320PZ-6

Failure code [DHH1KY] HST oil pressure sensor: Hot short SEN04195-01
WA320, 320PZ-6 40-360 15

SEN04195-01 Failure code [DHTCL6] HST filter clogging sensor: Functional defect
Failure code [DHTCL6] HST filter clogging sensor: Functional defect

Action code Failure code HST filter clogging sensor: Functional defect
Trouble
E01 DHTCL6 (Machine monitor system)
Contents of
When engine stopped, HST filter clogging sensor was turned ON (Ground fault was detected).
trouble
Action of
Turns HST filter clogging caution lamp OFF.
machine monitor
Problem that
appears on Foreign matter may enter HST hydraulic circuit.
machine
Related Input state (ON/OFF) of HST filter clogging sensor can be checked with monitoring function.

Defective HST filter clogging without turning starting switch ON.
1
sensor (Internal defect) Resis-
Possible causes Wiring harness between T13 T14 Min. 1 Mz
tance
and standard
state 2 ness (Contact with GND cir-
Min. 1 Mz
T13 and ground tance
If causes 1 2 are not detected, machine monitor may be defective.
40-360 16 WA320, 320PZ-6

Failure code [DHTCL6] HST filter clogging sensor: Functional defect SEN04195-01
WA320, 320PZ-6 40-360 17

SEN04195-01 Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short
Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short

Action code Failure code Fuel level sensor: Disconnection/Hot short
Trouble
E01 DJF1KA (Machine monitor system)
Contents of
Voltage above 4 V was detected in fuel level sensor signal circuit.
trouble
Action of
None in particular.
machine monitor
Problem that
appears on Fuel level gauge does not indicated normally (but keeps indicating empty).
machine
Input signal from fuel level sensor can be checked with monitoring function.
Related (Monitoring code: MONITOR PANEL 04200 FUEL SENSOR (V))
information (Monitoring code: MONITOR PANEL 04202 FUEL SENSOR (%))

Defective fuel level sensor R21 (male) Fuel level Resistance

1
(Internal defect) When full 7 11 z
Between (1) (2) When 1/2 25 35 z
When empty 60 95 z
2 Max. 1 z
or defective contact in con- R21 (female) (1) tance
Possible causes nector) Wiring harness between L26 (female) (6) Resis-
Max. 1 z
and standard R21 (female) (2) tance
state and carry out troubleshooting.
3 R21 (female) (1) and ground Voltage Max. 2 V
(Value is upper limit when empty.)
Voltage Max. 1 V
R21 (female) (2)
L26, L28 Fuel level Voltage
When full 0.1 0.4 V
Between L28 (1)
When 1/2 0.7 1.0 V
L26 (6)
When empty 1.4 2.0 V
40-360 18 WA320, 320PZ-6

Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short SEN04195-01
WA320, 320PZ-6 40-360 19

SEN04195-01 Failure code [DLT3KX] Travel speed sensor B: Abnormality
Failure code [DLT3KX] Travel speed sensor B: Abnormality

Action code Failure code Travel speed sensor B: Abnormality
Trouble
E03 DLT3KX (HST controller system)
Contents of While machine was traveling at speed above about 4 km/h, input signal of travel speed sensor B was
trouble lost.
Action of Recognizes travel speed by input signal of travel speed sensor A.
Problem that
appears on None in particular.
machine
Related If failure code [DLT3KX] and [DLT4KX] (Travel speed sensor A: Abnormality) are turned ON simulta-
information neously, see causes 6 and after.

a Prepare with starting switch OFF, then start engine (but do not
travel) and carry out troubleshooting.
T09 Voltage
Between (1) (2) 4.7 5.3 V
Defective travel speed sen- Between (2) ground Max. 1 V
1
sor (Internal defect) a Prepare with starting switch OFF, then start engine, travel at con-
stant speed, and carry out troubleshooting.
T09 Voltage
Below 1 V Above 4 V
Between (4) (2)
(Changes at regular intervals)
2
nector) Max. 1 z
T09 (female) (4) tance
Possible causes
and standard
value in normal
state Between wiring harness HST (female) (36) Resis-
Min. 1 Mz
Ground fault in wiring har- a Prepare with starting switch OFF, then start engine, travel at con-
3 ness (Contact with GND cir- stant speed, and carry out troubleshooting.
cuit) Below 1 V
Above
Between wiring harness HST (36) T09 (4) 4V
Voltage
and ground (Changes
at regular
intervals)
a Prepare with starting switch OFF, then start engine, travel at con-
Below 1 V
Hot short (Contact with 5 V, Above
4
24V circuit) in wiring harness Between wiring harness HST (36) T09 (4) 4V
Voltage
and ground (Changes
at regular
intervals)
40-360 20 WA320, 320PZ-6

Failure code [DLT3KX] Travel speed sensor B: Abnormality SEN04195-01

troubleshooting without traveling.
HST Voltage
Possible causes Between (22) (32) 4.7 5.3 V
and standard
value in normal Between (32) ground Max. 1 V
state a Prepare with starting switch OFF, then start engine, travel at con-
HST Voltage
Below 1 V Above 4 V
Between (36) (32)
WA320, 320PZ-6 40-360 21

SEN04195-01 Failure code [DLT3KX] Travel speed sensor B: Abnormality
a When [DLT3KX] and [DLT4KX] (Travel speed sensor A: Abnormality) are turned ON simultaneously
Contents of While machine was traveling at speed above about 4 km/h, input signals of travel speed sensors A
trouble and B were lost.
Keeps outputs to HST motor 1, HST motor 2 and clutch at values before trouble.
Action of
Keeps output values after clutch is engaged or disengaged completely, if clutch is being controlled.
controller
Problem that
Travel speed does not increase or traction force is insufficient.
appears on
Machine monitor indicates 0 km/h as travel speed.
machine
If trouble occurs while machine is stopped or traveling at low speed (below about 4 km/h), error is not
Related turned ON.
information In above case, machine monitor indicates 0 km/h as travel speed and actual travel speed is limited to
4 7 km/h.

T09 Voltage
Between (1) (2) 4.7 5.3 V
6
Defective travel speed sen- a Prepare with starting switch OFF, then start engine, travel at con-
sor (Internal defect) stant speed, and carry out troubleshooting.
T09 Voltage
Below 1 V Above 4 V
Between (3) (2)
Below 1 V Above 4 V
Between (4) (2)
Possible causes Max. 1 z
and standard Disconnection in wiring har- T09 (female) (1) tance
value in normal ness (Disconnection in wiring Wiring harness between HST (female) (32) Resis-
7 Max. 1 z
state or defective contact in con- T09 (female) (2) tance
nector) Wiring harness between HST (female) (26) Resis-
Max. 1 z
Max. 1 z
Between wiring harness HST (female) (22) Resis-
Ground fault in wiring har- Min. 1 Mz
Min. 1 Mz
Min. 1 Mz
9
24V circuit) in wiring harness Between wiring harness HST (32) T09 (2)
Voltage Max. 1 V
and ground
40-360 22 WA320, 320PZ-6

Failure code [DLT3KX] Travel speed sensor B: Abnormality SEN04195-01

HST Voltage
Between (22) (32) 4.7 5.3 V
Possible causes
and standard
value in normal 10 Defective HST controller a Prepare with starting switch OFF, then start engine, travel at con-
state stant speed, and carry out troubleshooting.
HST Voltage
Below 1 V Above 4 V
Between (26) (32)
Below 1 V Above 4 V
Between (36) (32)
WA320, 320PZ-6 40-360 23

SEN04195-01 Failure code [DLT4KX] Travel speed sensor A: Abnormality
Failure code [DLT4KX] Travel speed sensor A: Abnormality

Action code Failure code Travel speed sensor A: Abnormality
Trouble
E03 DLT4KX (HST controller system)
Contents of While machine was traveling at speed above about 4 km/h, input signal of travel speed sensor A was
trouble lost.
Action of Recognizes travel speed by input signal of travel speed sensor B.
Problem that
appears on None in particular.
machine
Related If failure code [DLT4KX] and [DLT3KX] (Travel speed sensor B: Abnormality) are turned ON simulta-
information neously, see [DLT3KX], causes 6 and after.

T09 Voltage
Between (1) (2) 4.7 5.3 V
Defective travel speed sen- Between (2) ground Max. 1 V
1
sor (Internal defect) a Prepare with starting switch OFF, then start engine, travel at con-
T09 Voltage
Below 1 V Above 4 V
Between (3) (2)
2
nector) Max. 1 z
Possible causes
and standard
value in normal
state Between wiring harness HST (female) (26) Resis-
Min. 1 Mz
Ground fault in wiring har- a Prepare with starting switch OFF, then start engine, travel at con-
3 ness (Contact with GND cir- stant speed, and carry out troubleshooting.
cuit) Below 1 V
Above
Between wiring harness HST (26) T09 (3) 4V
Voltage
and ground (Changes
at regular
intervals)
Below 1 V
Hot short (Contact with 5 V, Above
4
24V circuit) in wiring harness Between wiring harness HST (26) T09 (3) 4V
Voltage
and ground (Changes
at regular
intervals)
40-360 24 WA320, 320PZ-6

Failure code [DLT4KX] Travel speed sensor A: Abnormality SEN04195-01

HST Voltage
Possible causes Between (22) (32) 4.7 5.3 V
and standard
value in normal Between (32) ground Max. 1 V
state a Prepare with starting switch OFF, then start engine, travel at con-
HST Voltage
Below 1 V Above 4 V
Between (26) (32)
WA320, 320PZ-6 40-360 25

SEN04195-01 Failure code [DLT4LC] Travel speed sensor A & B: Abnormality
Failure code [DLT4LC] Travel speed sensor A & B: Abnormality

Action code Failure code Travel speed sensor A & B: Abnormality
Trouble
E03 DLT4LC (HST controller system)
Contents of
Difference between values sensed by travel speed sensors A and B during travel is large.
trouble
controller None in particular other than above (Uses higher value normally).
Problem that
appears on
machine
Related
Even trouble disappears, system does not reset itself until engine is started again.
information

travel) and carry out troubleshooting without traveling.
T09 Voltage
Between (1) (2) 4.7 5.3 V
1
Defective travel speed sen- a Prepare with starting switch OFF, then start engine, travel at con-
sor (Internal defect) stant speed, and carry out troubleshooting.
T09 Voltage
Below 1 V Above 4 V
Between (3) (2)
Below 1 V Above 4 V
Between (4) (2)
2 Max. 1 z
or defective contact in con- T09 (female) (3) tance
Possible causes
nector) Wiring harness between HST (female) (36) Resis-
value in normal T09 (female) (4) tance
3 ness (Contact with GND cir- Min. 1 Mz
cuit)
Min. 1 Mz
Below 1 V
Above
Between wiring harness HST (female) (26) 4V
Voltage
T09 (female) (3) and ground (Changes
Hot short (Contact with 5 V, at regular
4
24V circuit) in wiring harness intervals)
Below 1 V
Above
Between wiring harness HST (female) (36) 4V
Voltage
T09 (female) (4) (Changes
at regular
intervals)
40-360 26 WA320, 320PZ-6

Failure code [DLT4LC] Travel speed sensor A & B: Abnormality SEN04195-01

HST Voltage
Between (22) (32) 4.7 5.3 V
Possible causes
and standard
value in normal 5 Defective HST controller a Prepare with starting switch OFF, then start engine, travel at con-
state stant speed, and carry out troubleshooting.
HST Voltage
Below 1 V Above 4 V
Between (26) (32)
Below 1 V Above 4 V
Between (36) (32)
WA320, 320PZ-6 40-360 27

SEN04195-01 Failure code [DV00KY] Alarm buzzer: Hot short
Failure code [DV00KY] Alarm buzzer: Hot short

Action code Failure code Alarm buzzer: Hot short
Trouble
E01 DV00KY (Machine monitor system)
Contents of
The alarm buzzer output circuit is shorted with the power source.
trouble
Stops alarm buzzer output.
Action of Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
machine monitor If trouble occurs while backup alarm/lamp is in operation, backup alarm/lamp output is turned OFF.
If trouble occurs while ECSS is in operation, ECSS output is turned OFF.
Problem that Alarm buzzer does not sound.
appears on Backup alarm/lamp may not operate.
machine ECSS may not operate.
The output state (ON/OFF) to the alarm buzzer can be checked with the monitoring function.
Output state (ON/OFF) to backup alarm/lamp relay can be checked with monitoring function.
Related
(Code: MONITOR PANEL 40952 D-OUT-2)
information
Output state (ON/OFF) to ECSS relay can be checked with monitoring function.
(Code: MONITOR PANEL 40952 D-OUT-3)

Hot short in wiring harness and carry out troubleshooting.
cuit) Wiring harness between L24 (female) (14)
Voltage Max. 1 V
L46 (female) (2) and chassis ground
Possible causes and carry out troubleshooting.
and standard Remove the buzzer, then connect +24 V to L46 (male) (1) and
value in normal Defective alarm buzzer GND to L46 (male) (2).
state 2
(Internal short circuit) Alarm buzzer is
Alarm buzzer sounds
normal
Defective alarm
Alarm buzzer does not sound
buzzer
When above 1 and 2 are normal, failure on the machine monitor
3 Defective machine monitor can be suspected. (Since trouble is in system, troubleshooting
cannot be carried out.)
40-360 28 WA320, 320PZ-6

Failure code [DV00KY] Alarm buzzer: Hot short SEN04195-01
WA320, 320PZ-6 40-360 29

SEN04195-01 Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault
Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault

Action code Failure code Motor 2 solenoid: Disconnection/Ground fault
Trouble
E01 DW26KA (HST controller system)
Contents of Motor 2 cannot be controlled because of disconnection or ground fault in motor 2 solenoid relay out-
trouble put system.
Keeps output to motor 2 solenoid relay turned OFF (If there is ground fault, output cannot be turned
Action of
OFF actually).
controller
Problem that When there is disconnection: Travel speed is not limited and maximum speed is equivalent to 4th
appears on gear speed in 3rd speed range.
machine When there is ground fault: Travel speed is set equivalent to 3rd gear speed in 4th speed range.
Output state (ON/OFF) to motor 2 solenoid relay can be checked with monitoring function.
Related
(Monitoring code: HST 40980 D-OUT-16)
information
Method of reproducing failure code: Travel at speed above about 11 km/h in 4th speed range.

Replace motor 2 normal defective
solenoid relay (L103)
Defective motor 2 solenoid with another relay. Condition does not Relay (L103) is
1
relay (Internal defect) become normal normal
Resis- 200
tance 400 z
troubleshooting.
2 holding relay (Internal short relay. become normal. normal.
circuit)
value in normal Resis- 200
state tance 400 z
3 Max. 1 z
Max. 1 z
Min. 1 Mz
a Prepare with starting switch OFF, then start engine, travel, and
HST Condition Voltage
5 Defective HST controller Stopped Max. 1 V
Between (27) Speed range: 4th
ground Travel speed: Above 20 30 V
11 km/h
40-360 30 WA320, 320PZ-6

Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault SEN04195-01
WA320, 320PZ-6 40-360 31

SEN04195-01 Failure code [DW26KY] Motor 2 solenoid: Hot short
Failure code [DW26KY] Motor 2 solenoid: Hot short

Action code Failure code Motor 2 solenoid: Hot short
Trouble
E01 DW26KY (HST controller system)
Contents of
Motor 2 solenoid cannot be operated because of hot short in motor 2 solenoid relay output system.
trouble
Action of Keeps output to motor 2 solenoid relay turned OFF.
Problem that
When the gear is shifted to 3rd, travel speed is not limited and maximum travel speed is equivalent to
appears on
4th-gear speed.
machine
Related Output state (ON/OFF) to motor 2 solenoid relay can be checked with monitoring function.
information (Monitoring code: HST 40980 D-OUT-16)

Replace motor 2 normal defective
Defective motor 2 solenoid with another relay. Condition does not Relay (L103) is
1
and standard Resis- 200
value in normal tance 400 z
2 Voltage
circuit) in wiring harness Wiring harness between HST (female) (27)
(When Max. 1 V
L103 (female) (2)
stopped)
HST Voltage
40-360 32 WA320, 320PZ-6

Failure code [DW26KY] Motor 2 solenoid: Hot short SEN04195-01
WA320, 320PZ-6 40-360 33

SEN04195-01 Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short
Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short

Action code Failure code Fan reverse solenoid circuit: Hot short
Trouble
E01 DW7BKY (HST controller system)
Contents of Abnormal voltage was generated because of hot short in fan reverse solenoid relay output system
trouble when fan reverse solenoid relay output was turned ON.
Action of Keeps output to fan reverse solenoid turned OFF and stops fan reverse control function.
Problem that
appears on Fan does not reverse (Manual reverse function and automatic reverse function do not work).
machine
Output state (ON/OFF) to fan reverse solenoid relay can be checked with monitoring function.
Related (Monitoring code: HST 40980 D-OUT-17)
information Method of reproducing failure code: Start engine, wait for at least 30 seconds, and then press man-
ual reverse switch.

Replace fan reverse normal defective
Defective fan reverse sole- with another relay. Condition does not Relay (L104) is
1
noid relay (Internal defect) become normal normal
Possible causes Resis- 200

and standard tance 400 z
value in normal a Prepare with starting switch OFF, then start engine and carry out
state troubleshooting.
Hot short (Contact with 5 V, Voltage (In fan for-
2 20 30 V
24V circuit) in wiring harness Wiring harness between HST ward mode)
(female) (37) L104 (female) (2) Voltage (In fan
Max. 1 V
reverse mode)
troubleshooting.
3 Defective HST controller HST Fan condition Voltage
Between (37) In fan forward mode 20 30 V
ground In fan reverse mode Max. 1 V
40-360 34 WA320, 320PZ-6

Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short SEN04195-01
WA320, 320PZ-6 40-360 35

SEN04195-01 Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/

Ground fault
Action code Failure code Fan reverse solenoid circuit: Disconnection/Ground fault
Trouble
E01 DW7BKZ (HST controller system)
Contents of Fan reverse solenoid relay cannot be controlled because of disconnection or ground fault in fan
trouble reverse solenoid relay output system.
Action of Keeps output to fan reverse solenoid turned OFF and stops fan reverse control function.
Problem that Manual reverse function and automatic reverse function do not work.
appears on Fan always turns forward (When there is disconnection).
machine Fan always turns in reverse (When there is ground fault).
Output state (ON/OFF) to fan reverse solenoid relay can be checked with monitoring function.
Related
information

Replace fan reverse normal defective
Defective fan reverse sole- with another relay. Condition does not Relay (L104) is
1
noid relay (Internal defect) become normal normal
Resis- 200
tance 400 z
troubleshooting.
2 holding relay (Internal short relay. become normal. normal.
Possible causes circuit)
state Resis- 200
tance 400 z
3 Max. 1 z
Max. 1 z
Min. 1 Mz
troubleshooting.
5 Defective HST controller HST Fan condition Voltage
Between (37) In fan forward mode 20 30 V
ground In fan reverse mode Max. 1 V
40-360 36 WA320, 320PZ-6

Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault SEN04195-01
WA320, 320PZ-6 40-360 37

SEN04195-01

2009 KOMATSU
All Rights Reserved
40-360 38
SEN04196-00
WA320-6
WA320PZ-6
WA320-6 70001 and up


Failure code [DX16KA] Fan EPC solenoid: Disconnection............................................................................. 2
Failure code [DX16KB] Fan EPC solenoid: Ground fault................................................................................ 3
Failure code [DX16KY] Fan EPC solenoid: Hot short..................................................................................... 4
Failure code [DX19KA] Motor 1 solenoid: Disconnection ............................................................................... 6
Failure code [DX19KB] Motor 1 solenoid: Ground fault .................................................................................. 8
Failure code [DX19KY] Motor 1 solenoid: Hot short ..................................................................................... 10
Failure code [DX20KA] Clutch EPC solenoid: Disconnection....................................................................... 12
Failure code [DX20KB] Clutch EPC solenoid: Ground fault.......................................................................... 14
Failure code [DX20KY] Clutch EPC solenoid: Hot short............................................................................... 16
Failure code [DXH7KB] Reverse solenoid: Ground fault .............................................................................. 18
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short ............................................................ 20
Failure code [DXH8KB] Forward solenoid: Ground fault .............................................................................. 22
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short ............................................................ 24
Failure code [J141N1] Steering pump: Overrun alarm.................................................................................. 26
Failure code [M100N1] HST pump: Overrun alarm ...................................................................................... 26
Failure code [M400N1] Motor 1: Overrun alarm ........................................................................................... 27
WA320, 320PZ-6 40-370 1

SEN04196-00 Failure code [DX16KA] Fan EPC solenoid: Disconnection
Failure code [DX16KA] Fan EPC solenoid: Disconnection 1
Action code Failure code Fan EPC solenoid: Disconnection

Trouble
E01 DX16KA (HST controller system)
Contents of Since the fan EPC solenoid system is disconnected, no current flows when the fan EPC solenoid
trouble output is ON.
Action of
Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
controller
Problem that
appears on The fan speed is set to the maximum.
machine
If [DX16KY] is displayed, carry out troubleshooting for it first.
Related The output state (current) to the fan EPC solenoid can be checked with the monitoring function
information (Code: HST 41400 FAN EPC DIR).

Defective fan EPC solenoid without turning starting switch ON.
1
(Internal disconnection) R29 (male) Resistance
Between (1) (2) 5 10 z
Possible causes
state ness Wiring harness between HST (female) (40) Resis-
2 Max. 1 z
(Disconnection or defective R29 (female) (2) tance
contact in connector) Wiring harness between HST (female) (29) Resis-
Max. 1 z
R29 (female) (1) tance
If causes 1 2 are not detected, HST controller may be defective.
40-370 2 WA320, 320PZ-6

Failure code [DX16KB] Fan EPC solenoid: Ground fault SEN04196-00
Failure code [DX16KB] Fan EPC solenoid: Ground fault 1
Action code Failure code Fan EPC solenoid: Ground fault

Trouble
E01 DX16KB (HST controller system)
Contents of Since the fan EPC solenoid system is shorted, abnormal current flows when the fan EPC solenoid
trouble output is ON.
Action of Turns the output to the fan EPC solenoid OFF.
controller Even if cause of failure disappears, system does not reset itself until starting switch is turned OFF.
Problem that
appears on The fan speed is set to the maximum.
machine
The output state (current) to the fan EPC solenoid can be checked with the monitoring function
Related
(Code: HST 41400 FAN EPC DIR).
information

Defective fan EPC solenoid R29 (male) Resistance
1
(Internal short circuit)
Possible causes Between (1) (2) 5 10 z
and standard Between (1), (2) and ground Min. 1 Mz
value in normal
state Grounding fault in wiring har- without turning starting switch ON.
2 ness
(Contact with ground circuit) Wiring harness between HST (female) (29) Resis-
Min. 1 Mz
R29 (female) (1) and ground tance
WA320, 320PZ-6 40-370 3

SEN04196-00 Failure code [DX16KY] Fan EPC solenoid: Hot short
Failure code [DX16KY] Fan EPC solenoid: Hot short 1
Action code Failure code Fan EPC solenoid: Hot short

Trouble
E01 DX16KY (HST controller system)
Contents of Since the fan EPC solenoid system is shorted with the power source, abnormal voltage is applied
trouble when the fan EPC solenoid output is OFF.
Action of Turns the output to the fan EPC solenoid OFF.
Problem that
appears on The fan speed is minimized.
machine
The output state (current) to the fan EPC solenoid can be checked with the monitoring function
Related
(Code: HST 41400 FAN EPC DIR).
information

Defective fan EPC solenoid R29 (male) Resistance
1
(Internal short circuit)
and standard Between (1), (2) and ground Min. 1 Mz
value in normal
state Hot short in wiring harness and carry out troubleshooting.
cuit) Wiring harness between HST (female) (29)
Voltage Max. 1 V
R29 (female) (1) and ground
40-370 4 WA320, 320PZ-6

Failure code [DX16KY] Fan EPC solenoid: Hot short SEN04196-00
WA320, 320PZ-6 40-370 5

SEN04196-00 Failure code [DX19KA] Motor 1 solenoid: Disconnection
Failure code [DX19KA] Motor 1 solenoid: Disconnection 1
Action code Failure code Motor 1 solenoid: Disconnection

Trouble
Contents of Disconnection was detected in motor 1 solenoid circuit.
trouble (Difference between output command value and actual current is large.)
Action of
controller
Traction force is decreased.
Problem that
appears on
machine If engine is stopped without applying parking brake securely on slope, machine moves down sud-
denly.
Related
information
If failure code [DX19KY] or [DX20KY] is also displayed, carry out troubleshooting for it first.

Defective motor 1 solenoid T06 (male) Resistance
1
(Internal defect)
Between (1) (2) 15 30 z
Between (1), (2) ground Min. 1 Mz
Max. 1 z
ness (Disconnection in wiring T06 (female) (1) tance
2
or defective contact in con- Wiring harness between T06 (female) (2) Resis-
nector) Max. 1 z
Possible causes
value in normal HST (female) (40) tance
Replace HST safety normal defective
relay (L111) with
another relay Condition does not Relay (L111) is
Defective HST safety relay become normal normal
3
(L111) (Internal defect)
a Prepare with starting switch OFF and check safety relay unit.
Apply 24 V between Resis-
Max. 1 z
Between L111 (male) (1) (2). tance
(3) (5) Apply no voltage Resis-
Min. 1 Mz
between (1) (2). tance
40-370 6 WA320, 320PZ-6

Failure code [DX19KA] Motor 1 solenoid: Disconnection SEN04196-00
WA320, 320PZ-6 40-370 7

SEN04196-00 Failure code [DX19KB] Motor 1 solenoid: Ground fault
Failure code [DX19KB] Motor 1 solenoid: Ground fault 1
Action code Failure code Motor 1 solenoid: Ground fault

Trouble
Contents of
Ground fault was detected in motor 1 solenoid circuit.
trouble
Action of
controller
Problem that
appears on
denly.

1
(Internal defect)
and standard Between (1), (2) ground Min. 1 Mz
value in normal
state Ground fault in wiring har- without turning starting switch ON.
Min. 1 Mz
Defective HST safety relay If causes 1 2 are not detected, HST controller may be defective.
3
(L111) (Internal defect) (Since trouble is in system, troubleshooting cannot be carried out.)
40-370 8 WA320, 320PZ-6

Failure code [DX19KB] Motor 1 solenoid: Ground fault SEN04196-00
WA320, 320PZ-6 40-370 9

SEN04196-00 Failure code [DX19KY] Motor 1 solenoid: Hot short
Failure code [DX19KY] Motor 1 solenoid: Hot short 1
Action code Failure code Motor 1 solenoid: Hot short

Trouble
Contents of
Hot short was detected in motor 1 solenoid circuit.
trouble
Action of
controller
Problem that
appears on
denly.
Related HST safety relay output: HST 40979 D_OUT_15 (ON/OFF)
information Clutch EPC solenoid output: HST 80100 CLUTCH SOL DIR (mA)
[DX19KA], [DX20KA] or [DX20KY] may be also displayed, depending on condition when error was
detected.

1
(Internal defect)
Between (1) (2) 15 30 z
Possible causes
and standard Between wiring harness T06 (female) (1)
Voltage Max. 1 V
value in normal HST (female) (19)
state Wiring harness between T06 (female) (2)
Hot short (Contact with 5 V, Voltage Max. 1 V
2 L111 (female) (3) and ground.
(Check with traction control OFF and machine stopped.)
Voltage 10 15 V
T06 (female) (1)
Defective HST safety relay If causes 1 2 are not detected, HST controller may be defective.
3
(L111) (Internal defect) (Since trouble is in system, troubleshooting cannot be carried out.)
40-370 10 WA320, 320PZ-6

Failure code [DX19KY] Motor 1 solenoid: Hot short SEN04196-00
WA320, 320PZ-6 40-370 11

SEN04196-00 Failure code [DX20KA] Clutch EPC solenoid: Disconnection
Failure code [DX20KA] Clutch EPC solenoid: Disconnection 1
Action code Failure code Clutch EPC solenoid: Disconnection

Trouble
Disconnection was detected in clutch EPC solenoid circuit.

Contents of
(When output command was above 250 mA, difference between command value and sensed cur-
trouble
rent exceeded 200 mA.)
Action of
controller
Problem that
appears on
denly.
Related
information
If failure code [DX19KY] or [DX20KY] is also displayed, carry out troubleshooting for it first.

Defective clutch EPC sole- T05 (male) Resistance
1
noid (Internal defect)
Between (1) (2) 5 15 z
Max. 1 z
2
or defective contact in con- Wiring harness between T05 (female) (2) Resis-
nector) Max. 1 z
Possible causes
value in normal HST (female) (40) tance
Replace HST safety normal defective
relay (L111) with
another relay Condition does not Relay (L111) is
Defective HST safety relay become normal normal
3
a Prepare with starting switch OFF and check safety relay unit.
Apply 24 V between Resis-
Max. 1 z
Between L111 (male) (1) (2). tance
(3) (5) Apply no voltage Resis-
Min. 1 Mz
between (1) (2). tance
40-370 12 WA320, 320PZ-6

Failure code [DX20KA] Clutch EPC solenoid: Disconnection SEN04196-00
WA320, 320PZ-6 40-370 13

SEN04196-00 Failure code [DX20KB] Clutch EPC solenoid: Ground fault
Failure code [DX20KB] Clutch EPC solenoid: Ground fault 1
Action code Failure code Clutch EPC solenoid: Ground fault

Trouble
Contents of
Ground fault was detected in clutch EPC solenoid circuit.
trouble
Action of
controller
Problem that
appears on
denly.

1
and standard Between (1), (2) ground Min. 1 Mz
value in normal
state Ground fault in wiring har- without turning starting switch ON.
Min. 1 Mz
40-370 14 WA320, 320PZ-6

Failure code [DX20KB] Clutch EPC solenoid: Ground fault SEN04196-00
WA320, 320PZ-6 40-370 15

SEN04196-00 Failure code [DX20KY] Clutch EPC solenoid: Hot short
Failure code [DX20KY] Clutch EPC solenoid: Hot short 1
Action code Failure code Clutch EPC solenoid: Hot short

Trouble
Contents of
Hot short was detected in clutch EPC solenoid circuit.
trouble
Action of
controller
Problem that
appears on
denly.
Related HST safety relay output: HST 40979 D_OUT_15 (ON/OFF)
information Clutch EPC solenoid output: HST 80100 CLUTCH SOL DIR (mA)
[DX19KA], [DX19KY] or [DX20KA] may be also displayed, depending on condition when error was
detected.

1
Between (1) (2) 5 15 z
Possible causes Between wiring harness HST (female) (9)
and standard Voltage Max. 1 V
T05 (female) (1) and ground
value in normal
state Between wiring harness L111 (female) (3)
Voltage Max. 1 V
Hot short (Contact with 5 V, T05 (female) (2)
2
24V circuit) in wiring harness a Prepare with starting switch OFF, then turn starting switch ON
and carry out troubleshooting
(Troubleshoot with traction switch OFF and machine is stopped (do
not travel))
Voltage 10 15 V
40-370 16 WA320, 320PZ-6

Failure code [DX20KY] Clutch EPC solenoid: Hot short SEN04196-00
WA320, 320PZ-6 40-370 17

SEN04196-00 Failure code [DXH7KB] Reverse solenoid: Ground fault
Failure code [DXH7KB] Reverse solenoid: Ground fault 1
Action code Failure code Reverse solenoid: Ground fault

Trouble
E03 DXH7KB (HST controller system)
Contents of
Reverse solenoid is not turned ON.
trouble
Action of Turns output to reverse solenoid OFF.
Problem that
appears on Machine does not travel in reverse.
machine
Output state to HST pump R (Reverse) solenoid of HST controller can be checked with monitoring
Related
function.
information

Defective reverse solenoid T01 (male) Resistance
1
(Internal defect)
Between (3) (4) 15 30 z
(Internal defect)
Between T01B (male) (1) (2) No continuity
troubleshooting.
Possible causes Replace FR pressure normal defective
and standard select relay (L101)
value in normal Defective FR pressure select with another relay Condition does not Relay (L101) is
3
state relay (Internal defect) become normal normal
Resis- 200
tance 400 z
Min. 1 Mz
a Prepare with starting switch OFF, then start engine, release park-
ing brake, set directional lever in R position, and carry out trouble-
5 Defective HST controller shooting.
HST Voltage
40-370 18 WA320, 320PZ-6

Failure code [DXH7KB] Reverse solenoid: Ground fault SEN04196-00
WA320, 320PZ-6 40-370 19

SEN04196-00 Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short
Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short 1
Action code Failure code Reverse solenoid: Disconnection/Hot short

Trouble
E03 DXH7KZ (HST controller system)
Reverse solenoid is not turned ON (HST pressure selector relay does not operate) (when there is
Contents of
disconnection).
trouble
Reverse solenoid cannot be turned OFF (Where there is hot short).
Action of Turns output to reverse solenoid OFF.
Problem that Machine does not travel in reverse (when there is disconnection).
appears on Machine may start in reverse suddenly (when there is hot short).
machine Gear is not set in neutral (when there is hot short).
Output state to HST pump R (Reverse) solenoid of HST controller can be checked with monitoring
Related
function.
information

Defective reverse solenoid T01 (male) Resistance
1
(Internal defect)
Between (3) (4) 15 30 z
(Internal defect)
Between T01B (male) (2) (1) No continuity
Replace FR pressure normal defective
select relay (L101)
Defective FR pressure select with another relay Condition does not Relay (L101) is
3
value in normal Resis- 200
state Between L101 (male) (5) (6)
tance 400 z
4 Max. 1 z
nector) Wiring harness between T01 (female) (4) Resis-
Max. 1 z
ground tance
5
Voltage Max. 1 V
a Prepare with starting switch OFF, then start engine and release
parking brake, and carry out troubleshooting.
Directional lever
position
Between (20) R (Reverse) 20 30 V
40-370 20 WA320, 320PZ-6

Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short SEN04196-00
WA320, 320PZ-6 40-370 21

SEN04196-00 Failure code [DXH8KB] Forward solenoid: Ground fault
Failure code [DXH8KB] Forward solenoid: Ground fault 1
Action code Failure code Forward solenoid: Ground fault

Trouble
E03 DXH8KB (HST controller system)
Contents of
Forward solenoid is not turned ON.
trouble
Action of Turns output to forward solenoid OFF.
Problem that
appears on Machine does not travel forward.
machine
Output state to HST pump F (Forward) solenoid of HST controller can be checked with monitoring
Related
function.
information

Defective forward solenoid T01 (male) Resistance
1
(Internal defect)
Between (1) (2) 15 30 z
Possible causes 2 (See Testing and adjusting, Test procedure for diode.)
(Internal defect)
and standard
value in normal Between T01A (male) (1) (2) No continuity
Min. 1 Mz
ing brake, set directional lever in F position, and carry out trouble-
4 Defective HST controller shooting.
HST Voltage
40-370 22 WA320, 320PZ-6

Failure code [DXH8KB] Forward solenoid: Ground fault SEN04196-00
WA320, 320PZ-6 40-370 23

SEN04196-00 Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short
Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short 1
Action code Failure code Forward solenoid: Disconnection/Hot short

Trouble
E03 DXH8KZ (HST controller system)
Forward solenoid is not turned ON (HST pressure selector relay does not operate) (when there is
Contents of
disconnection).
trouble
Forward solenoid cannot be turned OFF (Where there is hot short).
Action of Turns output to forward solenoid OFF.
Problem that Machine does not travel forward (when there is disconnection).
appears on Machine may start forward suddenly (when there is hot short).
machine Gear is not set in neutral (when there is hot short).
Output state to HST pump F (Forward) solenoid of HST controller can be checked with monitoring
Related
function.
information

Defective forward solenoid T01 (male) Resistance
1
(Internal defect)
Between (1) (2) 15 30 z
(Internal defect)
Between T01A (male) (1) (2) No continuity
Possible causes Disconnection in wiring har- without turning starting switch ON.
and standard ness (Disconnection in wiring Wiring harness between HST (female) (10) Resis-
value in normal 3 Max. 1 z
state nector) Wiring harness between T01 (female) (2) Resis-
Max. 1 z
ground tance
4
Voltage Max. 1 V
a Prepare with starting switch OFF, then start engine and release
parking brake, and carry out troubleshooting.
Directional lever
position
Between (10) F (Forward) 20 30 V
40-370 24 WA320, 320PZ-6

Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short SEN04196-00
WA320, 320PZ-6 40-370 25

SEN04196-00 Failure code [J141N1] Steering pump: Overrun alarm
Failure code [J141N1] Steering pump: Overrun alarm 1
Action code Failure code Steering pump: Overrun alarm

Trouble
E02 J141N1 (HST controller system)
Contents of
Steering pump speed exceeded alarm operation set value.
trouble
Action of
controller
Problem that
appears on Steering pump may be broken (If it is broken, machine may not steer).
machine
Related Advance alarm is turned ON before this code is displayed.
information If steering pump speed decreases below alarm reset value, system resets itself.

and standard
value in normal a Give operator instructions to use engine in range where alarm is
1 Steering pump overrun
state not turned ON.
Failure code [M100N1] HST pump: Overrun alarm 1
Action code Failure code HST pump: Overrun alarm

Trouble
E02 M100N1 (HST controller system)
Contents of
HST pump speed exceeded alarm operation set value.
trouble
Action of
controller
Problem that
appears on HST pump may be broken (If it is broken, machine cannot travel).
machine
information If HST pump speed decreases below alarm reset value, system resets itself.

and standard
1 HST pump overrun
40-370 26 WA320, 320PZ-6

Failure code [M400N1] Motor 1: Overrun alarm SEN04196-00
Failure code [M400N1] Motor 1: Overrun alarm 1
Action code Failure code Motor 1: Overrun alarm

Trouble
E02 M400N1 (HST controller system)
Contents of
HST motor 1 speed exceeded alarm operation set value.
trouble
Action of
controller
Problem that
appears on HST motor 1 may be broken (If it is broken, machine cannot travel).
machine
information If HST motor 1 speed decreases below alarm reset value, system resets itself.

and standard
1 HST motor 1 overrun
WA320, 320PZ-6 40-370 27

SEN04196-00

2008 KOMATSU
All Rights Reserved
40-370 28
SEN04197-01
WA320-6
WA320PZ-6
WA320-6 70001 and up

400 Troubleshooting of electrical system

(E-mode)
E-1 Engine does not start ............................................................................................................................... 3
E-2 Preheater does not operate normally ..................................................................................................... 10
E-3 Travel speed is low or high..................................................................................................................... 14
E-4 ECSS does not operate.......................................................................................................................... 20
E-5 ECSS keeps operating ........................................................................................................................... 23
E-6 Defective boom kick-out function and cancellation ................................................................................ 26
E-7 Defective bucket positioner function and cancellation............................................................................ 30
E-8 Defective lift arm FLOATING holding function and cancellation............................................................. 34
E-9 Travel direction selection system does not function ............................................................................... 38
E-10 Fan does not reverse ........................................................................................................................... 42
E-11 Fan keeps rotating in reverse ............................................................................................................... 46
E-12 Wiper does not operate ........................................................................................................................ 48
E-13 Windshield washer does not operate ................................................................................................... 52
E-14 Headlamp, clearance lamp and tail lamp do not light up or go off........................................................ 56
E-15 Working lamp does not light up or go off .............................................................................................. 64
E-16 Turn signal lamp and hazard lamp do not light up or go off ................................................................. 70
E-17 Brake lamp does not light or it keeps lighting up .................................................................................. 76
E-18 Backup lamp does not light or it keeps lighting up ............................................................................... 78
E-19 Backup alarm does not sound or it keeps sounding............................................................................. 81
E-20 Horn does not sound or it keeps sounding........................................................................................... 84
E-21 Alarm buzzer does not sound or it keeps sounding ............................................................................. 86
WA320, 320PZ-6 40-400 1

400 Troubleshooting of electrical system (E-mode)
SEN04197-01
E-22 Air conditioner does not operate or stop............................................................................................... 88

E-23 The KOMTRAX system does not work properly................................................................................... 92
40-400 2 WA320, 320PZ-6

E-1 Engine does not start SEN04197-01
E-1 Engine does not start 1
Contents of
trouble
Before starting troubleshooting, check the following.
a. Directional lever is in N (Neutral).
b. Directional switch is in N (Neutral).
c. Starting of engine is prohibited by function of KOMTRAX.
d. Battery cable is not disconnected from battery.
Related The engine does not start, because the starting motor does not run due to troubles in the starting
information motor system and starting switch terminal C signal system.
Check that fuse is normal.
(If it is broken, check the related wiring harness for grounding fault.)
The input state (ON/OFF) to the machine monitor from the starting switch terminal C can be checked
with the monitoring function (Code: MONITOR PANEL 40900, D-IN-2).
If failure code is indicated, carry out troubleshooting for it first.

Specific gravity Min. 1.26
1 Defective battery
Voltage Min. 25 V
The battery relay can be judged normal if operating sounds are audible
Defective battery relay
2 when the starting switch is operated.
(Internal defect)
Starting switch operation in the order of OFF o ON o OFF
If the fuse is burn, the circuit probably has a grounding fault, etc. (See
3 Defective fuse
cause 18.)
a Prepare with starting switch OFF (with wiring harness connected),
then turn starting switch START and carry out troubleshooting
Starting motor Voltage
Between terminals B (E30)
Defective starting motor Power supply input 20 30 V
4 and ground
(Internal defect)
Between terminals C (E21)
Starting input 20 30 V
and ground
If the starting motor does not run even if power supply input, battery
Possible
input and starting input is normal, the starting motor is defective.
causes and
standard value a Prepare with starting switch OFF, then turn starting switch ON and
in normal state Defective alternator carry out troubleshooting.
5
(Internal defect) Wiring harness between alternator terminal R
Voltage Max. 1 V
E02 (female) (1) ground
a Prepare with starting switch OFF, then carry out troubleshooting with
starting OFF and START each.
L02 (male) Position of switch Resistance
Defective starting switch OFF Min. 1 Mz
6
(Internal defect) Between (1) and (3)
START Max. 1 z
Between (1) and (2) OFF Min. 1 Mz
Between (1) and (4) ON Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON and
Defective FNR lever switch FNR (directional)
7 (Internal disconnection or MF1 (male) Voltage
lever
short circuit)
N (Neutral). 20 30 V
Between (1) and (3)
Other than above Max. 1 V
WA320, 320PZ-6 40-400 3

SEN04197-01 E-1 Engine does not start

a Prepare with starting switch OFF, then carry out troubleshooting with-
out turning starting switch ON.
Defective directional L63 (male) Switch position Resistance
8 selector switch actuation ON (Directional
switch (Internal defect) Max. 1 z
switch is selected)
Between (3) (4)
OFF
Min. 1 Mz
(Lever is selected)
D21 (male) Diode range Continuity
Defective diodes (D21, Measure at (2) in
Between (2) and (1) Continue
D22) (Internal defect) diode range.
9
a Only when both diodes a Prepare with starting switch OFF, then carry out troubleshooting with-
are detective out turning starting switch ON.
Measure at (2) in
diode range.
Defective diodes (D01)
10 Measure at (5) in
(Internal defect) Between (5) and (1) Continue
diode range.
Possible Measure at (6) in
causes and diode range.
standard value a Prepare with starting switch OFF, then carry out troubleshooting with-
in normal state out turning starting switch ON.
11 Measure at (7) in
(Internal defect) Between (7) and (3) Continue
diode range.
Measure at (8) in
diode range.
Defective diode (D10)
12 D10 (male) Diode range Continuity
(Internal defect)
Measure on (2) side
Between (2) (1) Continuity is secured
in diode range
a Prepare with starting switch OFF (with wiring harness connected),
then carry out troubleshooting without turning starting switch ON.
Starting motor safety relay Voltage
Between B-terminal
Power supply input 20 30 V
E20 E-terminal
Defective starting motor Between R-terminal E01
Charge input Max. 1 V
13 safety relay (male) (2) E-terminal
(Internal defect) Between S-terminal E01
Starting input 20 30 V
(male) (1) E-terminal
Between C-terminal
Output 20 30 V
E19 E-terminal
If power supply input and starting input are normal but output voltage is
low, starting motor safety relay is defective.
40-400 4 WA320, 320PZ-6


Between (1) and (2) 200 400 z
a Check neutral safety relay unit.
Neutral safety relay
(1) (2) Resistance
Defective neutral safety (L106)
14 relay (L106) When 24 V is applied
(Internal defect) Max. 1 z
(When relay is ON)
Between (3) (5)
Other than above
Min. 1 Mz
(When relay is OFF)
a Prepare with starting switch OFF, then turn starting switch to START
When neutral safety relay (L106) is replaced with a relay of the same
type, if the condition becomes normal, the neutral safety relay is defec-
tive.
L107 (male), L108 (male) Resistance
Possible
Between (1) and (2) 200 400 z
causes and
standard value a Prepare with starting switch OFF.
in normal state a Check engine control cut-out relay unit.
Engine control cut-out
(1) (2) Resistance
Defective engine control relay (L107), (L108)
15 cut-out relays (L107, When 24 V is applied
L108) (Internal defect) Max. 1 z
(When relay is ON)
Between (3) (5)
Other than above
Min. 1 Mz
(When relay is OFF)
When engine control cut-out relay (L107, L108) is replaced with a relay
of the same type, if the condition becomes normal, the engine control
cut-out relay is defective.
Between (1) and (2) 200 400 z
Defective KOMTRAX
16 engine cut-out relay (L79) Between (3) and (6) Min. 1 Mz
(Internal defect) a Prepare with starting switch OFF, then turn starting switch to START
When KOMTRAX engine cut-out relay (L79) is replaced with a relay of
the same type, if the condition becomes normal, the KOMTRAX engine
cut-out relay is defective.
WA320, 320PZ-6 40-400 5


Between (1) (2) 200 400 z
a Check VIS power supply holding relay
VIS power supply
(1) (2) Resistance
Defective VIS power sup- holding relay (L102)
17 ply holding relay (L102) When 24 V is applied
(Internal defect) Max. 1 z
(When relay is ON)
Between (3) (5)
Other than above
Min. 1 Mz
(When relay is OFF)
When VIS power supply holding relay (L102) is replaced with another
relay, if condition becomes normal, VIS power supply holding relay is
defective.
Wiring harness between battery relay R04 Resis-
Max. 1 z
starting motor terminal B (E30) tance
Between starting motor B-terminal E30 starting Resis-
Max. 1 z
Possible motor safety relay B-terminal E20 tance
causes and Between starting motor C-terminal E21 starting Resis-
standard value Max. 1 z
motor safety relay C-terminal E19 tance
in normal state
Wiring harness between L02 (female) (3) L79 Resis-
Max. 1 z
(female) (3) tance
Max. 1 z
(female) (3) tance
Wiring harness between L106 (female) (5) E01 Resis-
Max. 1 z
(female) (1) tance
Disconnection in wiring Wiring harness between L15 (female) (3) L106 Resis-
harness Max. 1 z
(female) (1) tance
18 (Disconnection in wiring
harness or defective con- Max. 1 z
tact) MF1 (female) (3), L63 (female) (3) tance
Wiring harness between MF1 (female) (1), L63 Resis-
Max. 1 z
(female) (4) ground tance
Max. 1 z
(female) (1), L108 (female) (1) tance
Wiring harness between L02 (female) (4) EC2 Resis-
Max. 1 z
(female) (2) tance
Wiring harness between L107 (female) (2), L108 Resis-
Max. 1 z
(female) (2) EC2 (female) (33) tance
Wiring harness between fuse No. 4 of fuse box Resis-
Max. 1 z
(FS1) L107 (female) (3), L108 (female) (3) tance
Max. 1 z
(female) (5) EC3 (female) (3), (4) tance
Wiring harness between EC3 (female) (1), (2) Resis-
Max. 1 z
ground tance
40-400 6 WA320, 320PZ-6


Wiring harness between battery relay R04 Resis-
Min. 1 Mz
starting motor terminal B (E30) and ground tance
Between wiring harness starting motor B-termi-
Resis-
nal E30 starting motor safety relay B-terminal Min. 1 Mz
tance
E20 and ground
Between wiring harness starting motor C-termi-
Resis-
nal E21 starting motor safety relay C-terminal Min. 1 Mz
tance
E19 and ground
Min. 1 Mz
(female) (3), circuit branch end and ground tance
Min. 1 Mz
(female) (5) and ground tance
Wiring harness between L106 (female) (5) E01 Resis-
Ground fault in wiring har- (female) (1) and ground Min. 1 Mz
tance
ness
19 Between wiring harness L02 (female) (2) L107 Resis-
(Contact with ground cir- Min. 1 Mz
(female) (1), L108 (female) (1) and ground tance
cuit)
Between wiring harness L02 (female) (4) EC2 Resis-
Min. 1 Mz
(female) (2) and ground tance
Between wiring harness L15 (female) (3) L106 Resis-
Min. 1 Mz
Possible (female) (1) and ground tance
causes and Between wiring harness L102 (female) (3) L15 Resis-
Min. 1 Mz
standard value (female) (1) and ground tance
in normal state Between wiring harness fuse box (FS1) No. 3 Resis-
Min. 1 Mz
fuse L102 (female) (5) and ground tance
Min. 1 Mz
(female) (2) EC2 (female) (33) and ground tance
Wiring harness between fuse No. 4 of fuse box
Resis-
(FS1) L107 (female) (3), L108 (female) (3) and Min. 1 Mz
tance
ground
Min. 1 Mz
(female) (5) EC3 (female) (3), (4) and ground tance
a Prepare with starting switch OFF, then turn starting switch ON and
Hot short in wiring harness Wiring harness between L107 (female) (2), L108
20 (Contact with 5V, 24V cir- (female) (2) EC2 (female) (33), alternator ter-
cuit) minal R E02 (female) (1) E01 (female) (2),
Voltage Max. 1 V
circuit branch end and ground (Note: if hot short
occurs across them, the charging lamp will be
lighted as the starting switch is ON.
Between EC2 (33) ground Voltage Max. 1 V
Between EC2 (39) ground Voltage 20 30 V
Between EC3 (3), (4) ground Voltage 20 30 V
Between EC3 (1), (2) ground Voltage Max. 1 V
WA320, 320PZ-6 40-400 7

40-400 8 WA320, 320PZ-6

WA320, 320PZ-6 40-400 9

SEN04197-01 E-2 Preheater does not operate normally
E-2 Preheater does not operate normally 1
a) Preheater does not operate

Contents of
When temperature is low (engine boost air temperature is below 4C), preheater does not operate.
trouble
If failure codes are displayed, carry out troubleshooting for them first.
Related Engine boost air temperature can be checked with monitoring function.
information (Monitoring code: ENG-18500-CHG TEMP (C))
(Monitoring code: ENG-18501-CHG TEMP (V))

a Turn starting switch OFF and remove heater relay.
a Check heater relay unit.
Heater relay E06 R90 Resistance
Defective heater relay When 24 V is applied
1 Max. 1 z
(Internal defect) (When relay is ON)
Between E05 E07A
Other than above
Min. 1 Mz
(When relay is OFF)
Between E06 R90 19 25 z
Defective intake air heater without turning starting switch ON.
2
(Internal defect) Resis- 0.17
Between E07B ground
tance 0.27 z
a Replace diode (E06A).
Condition becomes normal. Diode (E06A) is defective.
Possible
causes and Condition does not become nor-
Diode (E06A) is normal.
standard value Defective diode (E06A) mal.
3
in normal state (Internal defect) a Prepare with starting switch OFF, then carry out troubleshooting
a Measure in diode range.
Between (2) (1)
Continuity is secured.
a Apply (+) side of tester to (2).
ness (Disconnection in wiring Resis-
4 Wiring harness between E07A E07B Max. 1 z
or defective contact in connec- tance
tor) Resis-
Wiring harness between R11 E05 Max. 1 z
tance
Ground fault in wiring harness Between wiring harness E07A E07B and Resis-
5 Min. 1 Mz
(Contact with GND circuit) ground tance
Between wiring harness R11 E05 and Resis-
Min. 1 Mz
ground tance
40-400 10 WA320, 320PZ-6

E-2 Preheater does not operate normally SEN04197-01
WA320, 320PZ-6 40-400 11

SEN04197-01 E-2 Preheater does not operate normally
b) Preheater operates constantly

Contents of
Preheater operates constantly.
trouble
If failure code [CA144] or [CA145] is displayed, carry out troubleshooting for it first.
Related Engine boost air temperature can be checked with monitoring function.
information (Monitoring code: ENG-18500-CHG TEMP (C))
(Monitoring code: ENG-18501-CHG TEMP (V))

a Turn starting switch OFF and remove heater relay.
a Check heater relay unit.
Heater relay E06 R90 Resistance
Defective heater relay When 24 V is applied
1 Max. 1 z
(Internal defect) (When relay is ON)
Between E05 E07A
Other than above
Min. 1 Mz
(When relay is OFF)
Between E06 R90 19 25 z
Possible a Prepare with starting switch OFF, then carry out troubleshooting
causes and Ground fault in wiring harness without turning starting switch ON.
2
standard value (Contact with GND circuit) Between wiring harness EC2 (40) E06 (5) Resis-
Min. 1 Mz
in normal state and ground tance
When
Hot short (Contact with 5V, preheater Voltage 20 30 V
3
24V circuit) in wiring harness Between wiring harness E07A is ON
E07B and ground When
preheater Voltage Max. 1 V
is OFF
If cause 1 3 are not detected, engine controller may be defective.

a See the circuit diagram in E-2 a) Preheater does not operate.
40-400 12 WA320, 320PZ-6

E-2 Preheater does not operate normally SEN04197-01
WA320, 320PZ-6 40-400 13

SEN04197-01 E-3 Travel speed is low or high
E-3 Travel speed is low or high 1
a) Max. speed is 7 km/h or below and speedometer indicates 0 km/h

Contents of Travel speed does not increase above 4 7 km/h.
trouble Speedometer of machine monitor keeps indicating 0 km/h during travel.
Related
If failure code [DLT3KX] or [DLT4KX] is also displayed, carry out troubleshooting for it first.
information

T09 Voltage
Between (1) (2) 4.7 5.3 V
Defective travel speed sensor a Prepare with starting switch OFF, then start engine, travel at con-
1
(Internal defect) stant speed, and carry out troubleshooting.
T09 Voltage
Below 1 V Above 4 V
Between (3) (2)
Below 1 V Above 4 V
Between (4) (2)
Possible Max. 1 z
causes and Disconnection in wiring har- T09 (female) (1) tance
standard value ness (Disconnection in wiring Wiring harness between HST (female) (32) Resis-
2 Max. 1 z
in normal state or defective contact in connec- T09 (female) (2) tance
tor) Wiring harness between HST (female) (26) Resis-
Max. 1 z
Max. 1 z
Min. 1 Mz
Ground fault in wiring harness T09 (female) (1) and ground tance
3
(Contact with GND circuit) Between wiring harness HST (female) (26) Resis-
Min. 1 Mz
Min. 1 Mz
4
24V circuit) in wiring harness Between wiring harness HST (32) T09 (2)
Voltage Max. 1 V
and ground
40-400 14 WA320, 320PZ-6

E-3 Travel speed is low or high SEN04197-01

HST Voltage
Between (22) (32) 4.7 5.3 V
Possible
causes and
standard value 5 Defective HST controller a Prepare with starting switch OFF, then start engine, travel at con-
in normal state stant speed, and carry out troubleshooting.
HST Voltage
Below 1 V Above 4 V
Between (26) (32)
Below 1 V Above 4 V
Between (36) (32)
WA320, 320PZ-6 40-400 15

b) When speed range is set to 3rd speed, speed is not limited and max. travel speed is at 4th speed
level
Contents of When speed range is set to 3rd speed, speed is not limited and max. travel speed is at 4th speed
trouble level.
Related
If failure code [DW26KA] or [DW26KY] is also displayed, carry out troubleshooting for it first.
information

troubleshooting.
Replace HST motor 2 normal. defective.
with another relay. Condition does not Relay (L103) is
become normal. normal.
Defective HST motor 2 sole- a Prepare with starting switch OFF.
1
noid relay (Internal defect) a Check relay unit.
HST motor 2 solenoid
(1) (2) Resistance
relay (L103)
When 24 V is applied
Max. 1 z
(Relay is ON)
Between (3) (5)
Other than above
Possible Min. 1 Mz
(Relay is OFF)
causes and
standard value a Prepare with starting switch OFF, then carry out troubleshooting
in normal state Defective HST motor 2 sole- without turning starting switch ON.
2
noid (Internal defect) Resis- 15 30
Between T07 (male) (1) T07 (male) (2)
tance Mz
Max. 1 z
3
or defective contact in connec- Wiring harness between T07 (female) (2) Resis-
tor) Max. 1 z
ground tance
Max. 1 z
Ground fault in wiring harness without turning starting switch ON.
4
(Contact with GND circuit) Between wiring harness L103 (female) (5) Resis-
Min. 1 Mz
40-400 16 WA320, 320PZ-6

WA320, 320PZ-6 40-400 17

c) When speed range is set to 4th speed, max. speed does not increase above 3rd gear speed level
Contents of
When speed range is set to 4th speed, max. speed does not increase above 3rd gear speed level.
trouble
Related
If failure code [DW26KA] is also displayed, carry out troubleshooting for it first.
information

troubleshooting.
Replace HST motor 2 normal. defective.
with another relay Condition does not Relay (L103) is
become normal. normal.
Defective HST motor 2 sole- a Prepare with starting switch OFF.
Possible 1
noid relay (Internal defect) a Check relay unit.
causes and
standard value HST motor 2
(1) (2) Resistance
in normal state solenoid relay (L103)
Max. 1 z
(Relay is ON)
Between (3) (5)
Other than above
Min. 1 Mz
(Relay is OFF)
Hot short (Contact with 24V and carry out troubleshooting.
2
circuit) in wiring harness Between wiring harness L103 (female) (5) Resis-
Max. 1 V
40-400 18 WA320, 320PZ-6

WA320, 320PZ-6 40-400 19

SEN04197-01 E-4 ECSS does not operate
E-4 ECSS does not operate 1
Contents of
When ECSS switch is turned ON, ECSS does not operate.
trouble
If failure code [D192KY] is also displayed, carry out troubleshooting for it first.
Related
information
Input state (ON/OFF) from ECSS switch can be checked with monitoring function.

Defective fuse No. 9 in fuse If fuse is broken, circuit probably has ground fault, etc.
1
box FS-2 (See cause 6.)
troubleshooting.
L09 (male) Switch position Resistance
ON Max. 1 z
Between (5) (6)
OFF Min. 1 Mz
Defective ECSS switch (Inter-
2 Between (5), (6)
nal defect) (Always) Min. 1 Mz
another terminal
Resis- 200
tance 400 z
troubleshooting.
Possible Defective ECSS solenoid Condition does not Relay (L110) is
3 another relay.
causes and relay (L110) (Internal defect) become normal. normal.
standard value
in normal state
Resis- 200
tance 400 z
Defective ECSS solenoid without turning starting switch ON.
4
(Internal defect) Resis-
Between F07 (male) (1) (2) 15 30 z
tance
Wiring harness between fuse box FS-2, No. Resis-
Max. 1 z
9 L09 (female) (6) tance
Max. 1 z
ness (Disconnection in wiring L25 (female) (5), L110 (female) (1), (3) tance
5
or defective contact in connec- Wiring harness between L24 (female) (11) Resis-
tor) Max. 1 z
Max. 1 z
F07 (female) (1) tance
Wiring harness between F07 (female) (2) Resis-
Max. 1 z
ground tance
40-400 20 WA320, 320PZ-6

E-4 ECSS does not operate SEN04197-01

Between wiring harness fuse box FS-2, No. Resis-
Min. 1 Mz
9 L09 (female) (6), branch end and ground tance
Ground fault in wiring harness
6 Between wiring harness L09 (female) (5)
(Contact with GND circuit) Resis-
Possible L25 (female) (5), L110 (female) (1), (3), Min. 1 Mz
causes and tance
branch end and ground
standard value
in normal state Min. 1 Mz
F07 (female) (1), branch end and ground tance
a Prepare with starting switch OFF, then turn ECSS switch ON,
start engine, and carry out troubleshooting.
Defective machine monitor or L24 Travel speed Voltage
7
HST controller
0 4 km/h 20 30 V
Between (5) (6)
Min. 5 km/h Max. 1 V
WA320, 320PZ-6 40-400 21

SEN04197-01 E-4 ECSS does not operate
40-400 22 WA320, 320PZ-6

E-5 ECSS keeps operating SEN04197-01
E-5 ECSS keeps operating 1
Contents of When ECSS switch is turned OFF, ECSS keeps operating.

trouble When ECSS switch is turned ON, ECSS operates even at low travel speed (4 km/h or below).
information Input state (ON/OFF) from ECSS switch can be checked with monitoring function.

troubleshooting.
ON Max. 1 z
Between (5) (6)
OFF Min. 1 Mz
Defective ECSS switch
1 Between (5), (6)
(Internal defect) (Always) Min. 1 Mz
another terminal
Resis- 200
tance 400 z
troubleshooting.
Defective ECSS solenoid another relay. Condition does not Relay (L110) is
2
relay (L110) (Internal defect) become normal. normal.
Possible Resis- 200
causes and tance 400 z
standard value
in normal state
Defective ECSS solenoid without turning starting switch ON.
3
Between F07 (male) (5) (6) 15 30 z
tance
Wiring harness between fuse box FS-2, No. Resis-
Max. 1 z
Max. 1 z
ness (Disconnection in wiring L25 (female) (5), L110 (female) (1), (3) tance
4
or defective contact in connec- Wiring harness between L24 (female) (11) Resis-
tor) Max. 1 z
Max. 1 z
F07 (female) (1) tance
Max. 1 z
ground tance
Ground fault in wiring harness Between wiring harness L24 (female) (11) Resis-
5 Min. 1 Mz
(Contact with GND circuit) L110 (female) (2) and ground tance
Reference: If above is defective, ECSS operates when ECSS switch
is turned ON even at low travel speed (4 km/h or below).
WA320, 320PZ-6 40-400 23

SEN04197-01 E-5 ECSS keeps operating

a Prepare with starting switch OFF, then turn starting switch ON,
turn ECSS switch OFF, and carry out troubleshooting.
6 L25 (female) (5), L110 (female) (1), (3), Voltage Max. 1 V
circuit) in wiring harness
Possible Voltage Max. 1 V
F07 (female) (1), branch end and ground
causes and
standard value a Prepare with starting switch OFF, then turn ECSS switch ON,
in normal state start engine, and carry out troubleshooting.
L24 Travel speed Voltage
Defective machine monitor or 0 4 km/h 20 30 V
7 Between (5) (6)
HST controller Min. 5 km/h Max. 1 V
turn ECSS switch OFF, and carry out troubleshooting.
Between L24 (11) ground Voltage Max. 1 V
40-400 24 WA320, 320PZ-6

E-5 ECSS keeps operating SEN04197-01
WA320, 320PZ-6 40-400 25

SEN04197-01 E-6 Defective boom kick-out function and cancellation
E-6 Defective boom kick-out function and cancellation 1
Contents of Boom kick-out does not function or cannot be cancelled due to defective boom kick-out proximity
trouble switch system, boom kick-out PPC detent system and lift arm detent relay system.
Related

information

a Replace boom kick-out relay (L113) with normal relay.
a Operate boom kick-out with engine started.
Boom kick-out function is normal. Defective relay L113.
Boom kick-out does not function. Relay L113 is normal.
a Turn starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective boom kick-out relay
1 Resis- 200 400
(L113) (Internal defect) Between L113 (male) (1) and (2)
tance z
a Solid part check.
Between Applies 24V impressed voltage Resis-
Max. 1 z
L113 between L113 (male) (1) (2) tance
(male) (3) Does not apply voltage between Resis-
and (5) Min. 1 Mz
L113 (male) (1) (2) tance
a Replace detent active relay (L115) with normal relay.
Boom kick-out function is normal. Defective relay L115.
Boom kick-out does not function. Relay L115 is normal.
Possible without turning starting switch ON.
causes and
Defective detent active relay Resis- 200 400
standard value 2 Between L115 (male) (1) and (2)
in normal state
(Internal defect) tance z
a Solid part check.
a Applies impressed voltage between L115 (male) (1) (2)
Max. 1 z
and (5) Min. 1 Mz
Prepare with starting switch OFF, then carry out troubleshooting
Defective boom kick-out PPC Resis-
3 Between L36 (male) (1) and (2) 30 50 z
detent (Internal defect) tance
Resis-
Between L36 (male) (1), (2) ground Min. 1 Mz
tance
a Interchange lift arm positioner proximity switch (F04) with bucket
positioner proximity switch (F03).
Defective lift arm positioner
Defective boom kick-
4 proximity switch (Internal
Boom kick-out function is normal. out proximity switch
defect)
F04
Boom kick-out prox-
Boom kick-out does not function. imity switch F04 is
normal.
40-400 26 WA320, 320PZ-6

E-6 Defective boom kick-out function and cancellation SEN04197-01

Wiring harness between F04 (female) (A) Resis-
Max. 1 z
and fuse (FS1) (13) tance
Wiring harness between F04 (female) (B) Resis-
Max. 1 z
and L113 (female) (2) tance
Wiring harness between F04 (female) (C) Resis-
Max. 1 z
and ground tance
Max. 1 z
Wiring harness discontinuity (3) and L115 (female) (5) tance
5 (Disconnection or defective Wiring harness between L115 (female) (3) Resis-
Max. 1 z
contact) and fuse FS1 (13) tance
Max. 1 z
Max. 1 z
and ground tance
Wiring harness between E02 (female) (1) Resis-
Max. 1 z
Max. 1 z
ground tance
a With all the above items, the boom kick-out does not function
causes and
standard value Wiring harness between F04 (female) (B) Resis-
Min. 1 Mz
in normal state and L113 (female) (2) and ground tance
Min. 1 Mz
and L36 (female) (1) and ground tance
a In this case, the boom kick-out detent does not function (lever
returns to neutral)
Wiring harness ground fault Wiring harness between F04 (female) (A) Resis-
6 Min. 1 Mz
(Contact with GND circuit) and fuse (FS1) (13) and ground tance
Min. 1 Mz
(3) and L115 (female) (5) and ground tance
Min. 1 Mz
and fuse FS1 (13) and ground tance
Min. 1 Mz
a In this case, the fuse is blown and no detents function (lever
returns to neutral)
Voltage Max. 1 V
Hot short-circuiting between L36 (female) (1) and ground
7 harnesses (Contact with 5 V, a In this case, the boom kick-out does not function (lever does not
24V circuit) return to neutral)
Wiring harness between L113 (female) (1),
Voltage Max. 1 V
(3) L115 (female) (5) and ground
a In this case, lift arm detent operates even if engine is stopped.
WA320, 320PZ-6 40-400 27

SEN04197-01 E-6 Defective boom kick-out function and cancellation

Possible raise lift arm to the highest position (kick-out operated), and carry
causes and Hot short-circuiting between out troubleshooting.
standard value 7 harnesses Wiring harness between F04 (female) (B)
in normal state Voltage Max. 1 V
(Contact with 5 V, 24V circuit) L113 (female) (2) and ground
a In this case, boom kick-out detent does not function (lever returns
to neutral).
40-400 28 WA320, 320PZ-6

E-6 Defective boom kick-out function and cancellation SEN04197-01
WA320, 320PZ-6 40-400 29

SEN04197-01 E-7 Defective bucket positioner function and cancellation
E-7 Defective bucket positioner function and cancellation 1
Contents of Bucket positioner does not function or cannot be cancelled due to defective bucket positioner proxim-
trouble ity switch system, bucket PPC detent system and bucket detent relay system.
Related

information

a Replace bucket leveler relay (L114) with normal relay.
a Operate bucket positioner with engine started.
Bucket positioner function is normal. Defective relay L114.
Bucket positioner does not function. Relay L114 is normal.
Defective bucket leveler relay Resis- 200 400
1 Between L114 (male) (1) and (2)
(L114) tance z
a Solid part check.
Max. 1 z
and (5) Min. 1 Mz
Possible a Turn starting switch OFF.
causes and a Replace detent active relay (L115) with normal relay.
standard value a Operate boom kick-out with engine started.
in normal state Boom kick-out function is normal. Defective relay L115.
Relay L115 is
Boom kick-out does not function.
normal.
Defective detent active relay
2 Resis- 200 400
(L113) Between L115 (male) (1) and (2)
tance z
a Solid part check.
Max. 1 z
and (5) Min. 1 Mz
3 Defective bucket PPC detent
Resis-
Between L37 (male) (1) and (2) 30 50 z
tance
40-400 30 WA320, 320PZ-6

E-7 Defective bucket positioner function and cancellation SEN04197-01

a Interchange bucket positioner proximity switch (F03) with lift arm
a Operate bucket positioner with engine started.
Defective bucket positioner Defective bucket
4
proximity switch Bucket positioner function is normal. positioner proximity
switch F03
Bucket positioner
Bucket positioner does not function. proximity switch F03
is normal.
Max. 1 z
and fuse FS1 (13) tance
Possible
causes and Max. 1 z
standard value and L114 (female) (2) tance
in normal state Wiring harness between F03 (female) (C) Resis-
Max. 1 z
and ground tance
Max. 1 z
Wiring harness discontinuity (3), and L115 (female) (5) tance
Max. 1 z
contact) and fuse FS1 (13) tance
Max. 1 z
Max. 1 z
and ground tance
Max. 1 z
Max. 1 z
ground tance
a With all the above items, the bucket positioner does not function
WA320, 320PZ-6 40-400 31

SEN04197-01 E-7 Defective bucket positioner function and cancellation

Min. 1 Mz
a In this case, the bucket positioner detent does not function (lever
does not return to neutral)
Min. 1 Mz
a In this case, the bucket positioner does not function (lever returns
to neutral)
6 Wiring harness ground fault
Min. 1 Mz
fuse FS1 (13) and ground tance
Min. 1 Mz
(3) L115 (female) (5) and ground tance
Min. 1 Mz
Possible Wiring harness between E02 (female) (1) Resis-
Min. 1 Mz
causes and L115 (female) (1) and ground tance
standard value a In this case, the fuse is blown and no detents function (lever
in normal state returns to neutral)
Voltage Max. 1 V
a In this case, the bucket positioner does not function (lever does
not return to neutral)
Voltage Max. 1 V
Hot short-circuiting between (3) L115 (female) (5) and ground
7 harnesses (Contact with 5 V, Wiring harness between E02 (female) (1)
Voltage Max. 1 V
24 V circuit) L115 (female) (1) and ground
a In this case, bucket detent operates even if engine is stopped.
a Prepare with starting switch OFF, then turn starting switch ON, tilt
bucket, and carry out troubleshooting.
Wiring harness between F03 (female) (B)
Voltage Max. 1 V
a In this case, bucket positioner detent does not function (lever
returns to neutral).
40-400 32 WA320, 320PZ-6

E-7 Defective bucket positioner function and cancellation SEN04197-01
WA320, 320PZ-6 40-400 33

SEN04197-01 E-8 Defective lift arm FLOATING holding function and cancellation
E-8 Defective lift arm FLOATING holding function and cancellation 1
Contents of Lift arm FLOATING holding does not function or cannot be cancelled due to defective boom kick-out
trouble proximity switch system, lift arm FLOATING PPC detent system and kick-out proximity switch system.
Related

information

a Replace boom kick-out relay (L113) with normal relay.
a Operate lift arm FLOATING with engine started.
Lift arm FLOATING function is normal. Defective relay L113.
Lift arm FLOATING does not function. Relay L113 is normal.
a Turn starting switch OFF, then carry out troubleshooting without
turning starting switch ON.
Defective boom kick-out relay
1 Resis- 200 400
(L113) (Internal defect) Between L113 (male) (1) (2)
tance z
a Solid part check.
Max. 1 z
and (5) Min. 1 Mz
a Replace detent active relay (L115) with normal relay.
Lift arm FLOATING function is normal. Defective relay L115.
Lift arm FLOATING does not function. Relay L115 is normal.
causes and
Defective detent active relay Resis- 200 400
standard value 2 Between L115 (male) (1) (2)
in normal state
(Internal defect) tance z
a Solid part check.
Max. 1 z
and (5) Min. 1 Mz
Prepare with starting switch OFF, then carry out troubleshooting
Defective lift arm FLOATING Resis-
3 Between L36 (male) (1) (2) 30 50 z
PPC detent (Internal defect) tance
Resis-
Between L35 (1), (2) ground Min. 1 Mz
tance
a Interchange lift arm positioner proximity switch (F04) with bucket
Defective lift arm positioner
Defective boom kick-
4 proximity switch (Internal
Lift arm FLOATING function is normal. out proximity switch
defect)
F04
Boom kick-out prox-
Lift arm FLOATING does not function. imity switch F04 is
normal.
40-400 34 WA320, 320PZ-6

E-8 Defective lift arm FLOATING holding function and cancellation SEN04197-01

Max. 1 z
fuse (FS1) (13) tance
Max. 1 z
Wiring harness between F04 (female) (C) Resis-
Max. 1 z
ground tance
Max. 1 z
Wiring harness discontinuity (3) L115 (female) (5) tance
Max. 1 z
contact) fuse FS1 (13) tance
Max. 1 z
Max. 1 z
ground tance
Max. 1 z
Max. 1 z
ground tance
a With all the above items, the boom kick-out does not function
causes and
standard value Wiring harness between F04 (female) (B) Resis-
Min. 1 Mz
in normal state L113 (female) (2) and ground tance
Min. 1 Mz
a In this case, the boom kick-out detent does not function (lever
returns to neutral)
Wiring harness ground fault Wiring harness between F04 (female) (A) Resis-
6 Min. 1 Mz
(Contact with GND circuit) fuse (FS1) (13) and ground tance
Min. 1 Mz
(3) L115 (female) (5) and ground tance
Min. 1 Mz
Wiring between harness E02 (female) (1) Resis-
Min. 1 Mz
a In this case, the fuse is blown and no detents function (lever
returns to neutral)
Voltage Max. 1 V
Hot short-circuiting between L35 (female) (1) and ground
7 harnesses (Contact with 5 V, a In this case, the boom kick-out does not function (lever does not
24V circuit) return to neutral)
Wiring between harness L113 (female) (1),
Voltage Max. 1 V
(3) L115 (female) (5) and ground
a In this case, lift arm detent operates even if engine is stopped.
WA320, 320PZ-6 40-400 35

SEN04197-01 E-8 Defective lift arm FLOATING holding function and cancellation

Possible operate lift arm FLOATING, and carry out troubleshooting.
causes and Hot short-circuiting between
standard value Wiring harness between F04 (female) (B)
7 harnesses Voltage Max. 1 V
in normal state L113 (female) (2) and ground
(Contact with 5 V, 24V circuit)
a In this case, lift arm FLOATING detent does not function (lever
returns to neutral).
40-400 36 WA320, 320PZ-6

E-8 Defective lift arm FLOATING holding function and cancellation SEN04197-01
WA320, 320PZ-6 40-400 37

SEN04197-01 E-9 Travel direction selection system does not function
E-9 Travel direction selection system does not function 1
a) When parking brake is released, parking brake indicator of machine monitor keeps lighting.
Contents of Machine does not travel forward and reverse because of trouble in parking brake system, forward
trouble solenoid valve system or directional lever system.
Before starting troubleshooting, check following items (1) and (2).
(1) Parking brake is released.
(2) Parking brake is released and parking brake indicator lamp is OFF.
If any failure code is displayed, carry out troubleshooting for it first.
Related
Input state of directional lever FNR input signal can be checked with indicator lamp or monitoring
information
function of machine monitor.
(Monitoring code: HST 40977 D-IN-0, D-IN-1, D-IN-2)
Output state of directional solenoid FR output can be checked with monitoring function.
(Monitoring code: HST 40980 D-OUT-18, D-OUT-19)

Defective parking brake bot- Parking brake
1 tom switch (Malfunction or L47 (male) Resistance
lever position
wrong positioning)
Bottom Max. 1 z
Between (1) (2)
Possible Disconnection in wiring har- without turning starting switch ON.
causes and ness (Disconnection in wiring Wiring harness between HST (female) (16), Resis-
standard value 2 Max. 1 z
or defective contact in connec- L27 (female) (1), (6) (2) L47 (female) (2) tance
in normal state tor) Resis-
L47 (female) (1) ground Max. 1 z
tance
3 Measure at (5) in
(Internal defect) Between (5) (1) Continue
diode range.
Measure at (7) in
Between (7) (3) Continue
diode range.
40-400 38 WA320, 320PZ-6

E-9 Travel direction selection system does not function SEN04197-01
WA320, 320PZ-6 40-400 39

SEN04197-01 E-9 Travel direction selection system does not function
b) When parking brake is released, parking brake indicator of machine monitor goes off but machine
does not travel forward
Contents of Machine does not travel forward because of trouble in parking brake system, forward solenoid valve
trouble system or directional lever system.
Before starting troubleshooting, check following items (1) and (2).
(1) Parking brake is released.
(2) Parking brake is released and parking brake indicator lamp is OFF.
If any failure code is displayed, carry out troubleshooting for it first.
Related
Input state of directional lever FNR input signal can be checked with indicator lamp or monitoring
information
function of machine monitor.
(Monitoring code: HST 40977 D-IN-0, D-IN-1, D-IN-2)
Output state of directional solenoid FR output can be checked with monitoring function.
(Monitoring code: HST 40980 D-OUT-18, D-OUT-19)

Resis-
1 Defective forward solenoid Between T01 (male) (1) (2) 30 60 z
(Internal defect) tance
Resis-
Between T01 (male) (1), (2) ground Min. 1 Mz
tance
Resis-
2 Defective reverse solenoid Between T01 (male) (3) (4) 30 60 z
(Internal defect) tance
Resis-
Between T01 (male) (3), (4) ground Min. 1 Mz
tance
FNR (Directional)
lever
F (Forward) Max. 1 z
Possible 3 Defective FNR (directional) Between (1) (2)
lever switch (Internal defect)
causes and
standard value N (Neutral) Max. 1 z
Between (1) (3)
in normal state Other than above Min. 1 Mz
R (Reverse) Max. 1 z
Between (1) (4)
ing brake, and carry out troubleshooting.
FNR (Directional)
HST Voltage
lever
N (Neutral) 20 30 V
Between (5) ground
Other than above Max. 1 V
40-400 40 WA320, 320PZ-6

E-9 Travel direction selection system does not function SEN04197-01
WA320, 320PZ-6 40-400 41

SEN04197-01 E-10 Fan does not reverse
E-10 Fan does not reverse 1
Contents of When fan manual reverse switch is turned ON, fan does not reverse.
trouble When fan auto-reverse switch is turned ON, fan does not reverse
If failure code [DD1NL4], [DW7BKY] or [DW7BKZ] is also displayed, carry out troubleshooting for it first.
Input state (ON/OFF) from fan manual reverse switch/auto-reverse switch can be checked with mon-
itoring function.
Related (Monitoring code: HST 93400 FAN REVERSE SW)
information (Manual reverse switch: Monitoring code: MONITOR PANEL 40900 D-IN-1)
(Auto- reverse switch: Monitoring code: MONITOR PANEL 40901 D-IN-9)
Output state (ON/OFF) to fan reverse solenoid relay can be checked in monitoring mode.

Defective fuse No. 13 in fuse
1 If fuse is broken, circuit probably has ground fault etc.
box (FS1)
without turning starting switch.
Manual reverse ON Max. 1 z
Between (5) (6)
Auto-reverse ON Max. 1 z
Between (5) (4)
Defective cooling fan auto- Other than above Min. 1 Mz
2 reverse switch (Internal
Between (5)
defect)
terminal other than Any position Min. 1 Mz
(4) and (6)
Between (4), (6) ter-
Any position Min. 1 Mz
minal other than (5)
Between (1), (3) (2) Any position 5 20 kz
Possible
causes and a Prepare with starting switch OFF.
standard value a Replace relay (L104).
in normal state Condition becomes normal. Relay (L104) is defective.
Condition does not become
Relay (L104) is normal.
normal.
Resis- 200
Defective fan reverse solenoid Between L104 (male) (1) (2)
3 tance 400 z
relay (L104) (Internal defect)
a Check relay unit.
Fan reverse solenoid
(1) (2) Resistance
relay (L104)
Max. 1 z
(When relay is ON)
Between (3) - (5)
Other than above
Min. 1 Mz
(When relay is OFF)
Defective fan reverse solenoid without turning starting switch ON.
4
Between R59 (male) (1) (2) 30 50 z
tance
40-400 42 WA320, 320PZ-6

E-10 Fan does not reverse SEN04197-01

Wiring harness between No. 13 in fuse box Resis-
Max. 1 z
(FS1) L69 (female) (5) tance
Max. 1 z
Disconnection in wiring har- L25 (female) (14) tance
5 Max. 1 z
or defective contact in connec- L25 (female) (10) tance
tor) Wiring harness between L102 (female) (3) Resis-
Max. 1 z
Max. 1 z
R59 (female) (1) tance
Possible
causes and Wiring harness between R59 (female) (2) Resis-
Max. 1 z
standard value ground tance
in normal state a Prepare with starting switch OFF, then carry out troubleshooting
Between wiring harness No. 13 in fuse box Resis-
Min. 1 Mz
Ground fault in wiring harness (FS1) L69 (female) (5) and ground tance
6
(Contact with GND circuit) Between wiring harness L69 (female) (3), (4) Resis-
Min. 1 Mz
Between wiring harness L69 (female) (1), (6) Resis-
Min. 1 Mz
a Prepare with starting switch OFF, then start engine, operate cool-
ing fan reverse switch, and carry out troubleshooting.
Defective machine monitor or HST Indicator Voltage
7
HST controller
Between (37) OFF 20 30 V
ground ON Max. 1 V
WA320, 320PZ-6 40-400 43

SEN04197-01 E-10 Fan does not reverse
40-400 44 WA320, 320PZ-6

E-10 Fan does not reverse SEN04197-01
WA320, 320PZ-6 40-400 45

SEN04197-01 E-11 Fan keeps rotating in reverse
E-11 Fan keeps rotating in reverse 1
Contents of When fan manual reverse switch is turned OFF, fan keeps rotating in reverse.
trouble When fan auto-reverse switch is turned OFF, fan starts rotating in reverse automatically.
If failure code [DD1NLD] or [DW7BKZ] is also displayed, carry out troubleshooting for it first.
Input state (ON/OFF) from fan manual reverse switch/auto-reverse switch can be checked with mon-
itoring function.
Related (Monitoring code: HST 93400 FAN REVERSE SW)
information (Manual reverse switch: Monitoring code: MONITOR PANEL 40900 D-IN-1)
(Auto-reverse switch: Monitoring code: MONITOR PANEL 40901 D-IN-9)
Output state (ON/OFF) to fan reverse solenoid relay can be checked in monitoring mode.

without turning starting switch.
Manual reverse ON Max. 1 z
Between (5) (6)
Auto-reverse ON Max. 1 z
Defective cooling fan auto- Between (5) (4)
1 reverse switch (Internal Other than above Min. 1 Mz
defect) Between (5) terminal
other than (4) and (6)
Between (1), (3) (2) Any position 5 20 z
a Replace relay (L104).
Condition becomes normal. Relay (L104) is defective.
Possible
Condition does not become
causes and Relay (L104) is normal.
normal.
standard value
Resis- 200
Defective fan reverse solenoid Between L104 (male) (1) (2)
2 tance 400 z
a Check relay unit.
Fan reverse solenoid
(1) (2) Resistance
relay (L104)
Max. 1 z
(When relay is ON)
Between (3) (5)
Other than above
Min. 1 Mz
(When relay is OFF)
Between wiring harness L69 (female) (3), (4)
Voltage Max. 1 V
Hot short (Contact with 5V, L25 (female) (14) and ground
3
24V circuit) in wiring harness Between wiring harness L69 (female) (1), (6)
Voltage Max. 1 V
Voltage Max. 1 V
R59 (female) (1) and ground
40-400 46 WA320, 320PZ-6

E-11 Fan keeps rotating in reverse SEN04197-01
Possible a Prepare with starting switch OFF, then start engine, operate cool-
causes and ing fan reverse switch, and carry out troubleshooting.
standard value Defective machine monitor or HST Indicator Voltage
4
in normal state HST controller
Between (37) OFF 20 30 V
ground ON Max. 1 V
WA320, 320PZ-6 40-400 47

SEN04197-01 E-12 Wiper does not operate
E-12 Wiper does not operate 1
Contents of
(1) Front wiper does not operate.
trouble
Related
The front wiper does not operate due to the defective front wiper switch, timer, or wiring harness.
information

1
L57 Front wiper switch Voltage
Defective front wiper motor Between (6) ground Constant 20 30 V
2
(Internal defect) Between (2) ground Lo 20 30 V
Between (1) ground Hi 20 30 V
If wiper switch is turned OFF while wiper is operating, voltage is
applied between L57 (5) and ground until wiper motor stops.
L48 Front wiper switch Voltage
Between (3) ground Constant 20 30 V
Possible Defective wiper timer (relay)
causes and 3 Between (4) ground INT 20 30 V
(Internal defect)
standard value Between (2) ground Washer side 20 30 V
in normal state
INT (If wiper switch is
Repeat 20 to 30 V o
Between (5) ground set in INT, voltage is
0V
output intermittently.)
L05 Voltage
Defective front wiper switch
4 L05 Front wiper switch Resistance
(Internal defect)
Between (7) (5) Lo Max. 1 z
Between (7) (4) Hi Max. 1 z
Between (7) (2) INT Max. 1 z
Between (3) (5) INT Max. 1 z
40-400 48 WA320, 320PZ-6

E-12 Wiper does not operate SEN04197-01

Max. 1 z
Disconnection in wiring har- Max. 1 z
ness
5 Wiring harness between L05 (female) (7)
(Disconnection or defective Resis-
contact in connector) fuse No. 14 of fuse box (FS1), circuit Max. 1 z
tance
branch end
Max. 1 z
Possible Wiring harness between L57 (female) (3) Resis-
causes and Max. 1 z
ground tance
standard value
in normal state
Resis-
L48 (female) (5), circuit branch end and Min. 1 Mz
tance
ground
Grounding fault in wiring har- Resis-
6 ness tance
ground
Resis-
fuse No. 14 of fuse box (FS1), circuit Min. 1 Mz
tance
Resis-
tance
ground
WA320, 320PZ-6 40-400 49

SEN04197-01 E-12 Wiper does not operate
Contents of
(2) Rear wiper does not operate.
trouble
Related
Since the rear wiper switch or wiring harness is defective, the rear wiper does not operate.
information

L52 Rear wiper switch Voltage
Defective rear wiper motor
1 Between (1) ground Constant 20 30 V
(Internal defect)
Between (2) ground ON 20 30 V
If wiper switch is turned OFF while wiper is operating, voltage is
applied between L52 (3) and ground until wiper motor stops.
L05 Voltage
Defective rear wiper switch a Prepare with starting switch OFF, then carry out troubleshooting
2 without turning starting switch ON.
(Internal defect)
L05 Rear wiper switch Resistance
Between (7) (9) ON Max. 1 z
Possible Between (8) (9) OFF Max. 1 z
causes and Other than above Min. 1 Mz
standard value
Max. 1 z
Disconnection in wiring har- fuse No. 14 of fuse box (FN1) tance
ness Wiring harness between L05 (female) (8) Resis-
3 Max. 1 z
(Disconnection or defective L52 (female) (3) tance
contact in connector) Wiring harness between L05 (female) (9) Resis-
Max. 1 z
Max. 1 z
ground tance
Resis-
Ground fault in wiring harness branch end and ground tance
4
Min. 1 Mz
Min. 1 Mz
40-400 50 WA320, 320PZ-6

E-12 Wiper does not operate SEN04197-01
WA320, 320PZ-6 40-400 51

SEN04197-01 E-13 Windshield washer does not operate
E-13 Windshield washer does not operate 1
Contents of
Windshield washer does not operate.
trouble
Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the
Related windshield washer does not operate.
information Perform the following troubleshooting when the wiper operates normally. (If the wiper does not oper-
ate normally, carry out troubleshooting for E-12 Wiper does not operate first.)

a Prepare with starting switch OFF, then hold starting switch OFF or
turn it ON and carry out troubleshooting.
B07 Front wiper switch Voltage/Resistance
Defective front washer motor
1 Between (1) ground Window washer 20 30 V
(Internal defect)
Between (2) ground operation position Max. 1 z
If voltage and resistance are normal but front washer does not oper-
ate, front washer motor is defective.
B06 Rear wiper switch Voltage/Resistance
Between (1) ground Window washer 20 30 V
Defective rear washer motor Between (2) ground operation position Max. 1 z
2
(Internal defect) If voltage and resistance are normal but rear washer does not oper-
ate, rear washer motor is defective.
B07 Front wiper switch Voltage/Resistance
L05 Voltage
Possible Between (7) ground 20 30 V
causes and a Prepare with starting switch OFF, then carry out troubleshooting
standard value without turning starting switch ON.
Defective front wiper switch
in normal state 3
(Internal defect) Washer switch for
front wiper
ON Max. 1 z
Between (7) (6)
OFF Min. 1 Mz
Between (7), (6)
Constant Min. 1 Mz
ground
L05 Voltage
Defective rear wiper switch without turning starting switch ON.
4
(Internal defect) Washer switch for
rear wiper
ON Max. 1 z
Between (7) (10)
OFF Min. 1 Mz
Between (7), (10)
Constant Min. 1 Mz
ground
40-400 52 WA320, 320PZ-6

E-13 Windshield washer does not operate SEN04197-01

Washer switch for
Defective wiper timer (relay) L48 Voltage
5 front wiper
(for only front wiper)
Between (3) ground Constant 20 30 V
Between (2) ground ON 20 30 V
Between (5) ground 0.2 0.8 sec after ON 20 30 V
Max. 1 z
Disconnection in wiring har- B07 (female) (1), L48 (female) (2) tance
Possible ness Wiring harness between L05(female) (7) Resis-
6 Max. 1 z
causes and (Disconnection or defective fuse No. 14 of fuse box (FS1) tance
standard value contact in connector) Wiring harness between L05 (female) (10) Resis-
in normal state Max. 1 z
B06 (female) (1) tance
Wiring harness between B07 (female) (2), Resis-
Max. 1 z
B06 (female) (2) ground tance
Resis-
B07 (female) (1), L48 (female) (2), circuit Min. 1 Mz
tance
7
tance
Resis-
B06 (female) (1), circuit branch end and Min. 1 Mz
tance
ground
WA320, 320PZ-6 40-400 53

SEN04197-01 E-13 Windshield washer does not operate
40-400 54 WA320, 320PZ-6

E-13 Windshield washer does not operate SEN04197-01
WA320, 320PZ-6 40-400 55

SEN04197-01 E-14 Headlamp, clearance lamp and tail lamp do not light up or go off
E-14 Headlamp, clearance lamp and tail lamp do not light up or go off 1
Contents of
(1) Headlamp, clearance lamp and tail lamp do not light up or go off.
trouble
Since the lamp system GND circuit is disconnected or shorted with the ground, none of the lamps
lights up.
Reference: Headlamp at SMALL position: Clearance lamp, tail lamp, machine monitor night lamp light
up (when normal).
Headlamp at HEAD position: Above lamps and headlamp light up (when normal).
Related
The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked
information
with the monitoring function (Code: MONITOR PANEL 40200, SMALL LAMP).
The input state (ON/OFF) to the machine monitor from the lamp switch (head lamp) can be checked
The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be checked

L04 (male) Lamp switch Resistance
OFF Min. 1 Mz
Defective lamp switch Between (2) (3) 1st line Min. 1 Mz
Possible 1
(Internal defect)
causes and 2nd line Max. 1 z
standard value OFF Min. 1 Mz
in normal state
Between (1) (3) 1st line Max. 1 z
2nd line Max. 1 z
2
(Disconnection or defective Wiring harness between L04 (female) (3) Resis-
connector contact) Max. 1 z
ground tance
40-400 56 WA320, 320PZ-6

E-14 Headlamp, clearance lamp and tail lamp do not light up or go off SEN04197-01
Contents of
(2) Either of headlamp (low and high beams) does not light up or go off.
trouble
The switch, lamp, or wiring harness of the headlamp (low and high beams) is defective.
Carry out the following troubleshooting when the clearance lamp and tail lamp light up and go off nor-
mally.
Related
information
The input state (ON/OFF) to the machine monitor from the dimmer switch (high beam) can be
checked with the monitoring function (Code: MONITOR PANEL 40904, D-IN-34).

Defective fuses No. 8 and No. If the fuse is burn, the circuit probably has a grounding fault, etc.
1
9 of fuse box (FS1) (See cause 7.)
Defective headlamp relay, left Between (1) (2) 200 400 z
2
(L120) (Internal defect) a Prepare with starting switch OFF, then turn starting switch ON
When headlamp relay (L120) is replaced with a relay of the same type,
if the condition becomes normal, the headlamp relay is defective.
Defective headlamp relay, Between (1) (2) 200 400 z
Possible 3
right (L119) a Prepare with starting switch OFF, then turn starting switch ON
causes and
standard value and carry out troubleshooting.
in normal state When headlamp relay (L119) is replaced with a relay of the same type,
if the condition becomes normal, the headlamp relay is defective.
Defective lamp switch L04 (male) Headlamp switch Resistance

4
(Internal defect) OFF Min. 1 Mz
Between (2) (3) 1st position Min. 1 Mz
2nd position Max. 1 z
L04 (male) Dimmer switch Resistance
Defective dimmer switch Low Min. 1 Mz
5
(Internal defect) Between (5) (3)
High Max. 1 z
Low Max. 1 z
Between (4) (3)
High Min. 1 Mz
WA320, 320PZ-6 40-400 57


Max. 1 z
Max. 1 z
box (FS1) L120 (female) (1), (3) tance
ness L25 (female) (1), left FLH (female) (B) tance
6
(Disconnection or defective a Carry out above 3 items when left side does not light.
Max. 1 z
Max. 1 z
Max. 1 z
right FLH (female) (B) tance
a Carry out above 3 items when right side does not light.
Resis-
tance
ground
a Carry out above when left side does not go off.
Possible
causes and Wiring harness between fuse No. 8 of fuse
Resis-
standard value box (FS1) L120 (female) (1), (3) and Min. 1 Mz
tance
in normal state ground
Resis-
Ground fault in wiring harness L25 (female) (1), left FLH (female) (B) and tance
Min. 1 Mz
7
(Contact with ground circuit) ground
a Carry out above 2 items when left side does not light.
Min. 1 Mz
a Carry out above when right side does not go off.
Wiring harness between fuse No. 9 of fuse
Resis-
box (FS1) L119 (female) (1), (3) and Min. 1 Mz
tance
ground
Min. 1 Mz
right FLH (female) (B) and ground tance
a Carry out above 2 items when right side does not light.
Headlamp switch is OFF
Hot short in wiring harness L25 (female) (1), left FLH (female) (B) and Voltage Max. 1 V
8
(Contact with 5 V, 24V circuit) ground
a Carry out above when left side does not go off.
Voltage Max. 1 V
right FLH (female) (B) and ground
a Carry out above when left side does not light.
40-400 58 WA320, 320PZ-6

Contents of
(3) Headlamp (low beam) does not light up or go off.
trouble
The switch, lamp, or wiring harness of the headlamp (low beam) is disconnected or shorted with the
ground.
Carry out the following troubleshooting when the high beam lights up (goes off) normally.
Related
information

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb
may have a defective contact. Check the bulb directly.
2
High Max. 1 z
Possible Low Max. 1 z
Between (4) (3)
causes and High Min. 1 Mz
standard value
in normal state
ness
3 Wiring harness between FLH (female) (A) Resis-
(Disconnection or defective Max. 1 z
contact in connector)
Reference: Connector FLH is installed to both right and left sides.
4 Wiring harness between FLH (female) (A) Resis-
(Contact with ground circuit) Min. 1 Mz
WA320, 320PZ-6 40-400 59

Contents of
(4) Headlamp (high beam) does not light up or go off.
trouble
The switch, lamp, or wiring harness of the headlamp (high beam) is disconnected or shorted with the
ground.
Carry out the following troubleshooting when the low beam lights up (goes off) normally.
Related
information

If a specific headlamp does not light up, its bulb may be broken or
1 Broken bulb
2
High Max. 1 z
Low Max. 1 z
Possible Between (4) (3)
causes and High Min. 1 Mz
in normal state Disconnection in wiring har- without turning starting switch ON.
ness
3 Wiring harness between FLH (female) (C) Resis-
(Disconnection or defective Max. 1 z
Ground fault in wiring harness Wiring harness between FLH (female) (C)
4 Resis-
(Contact with ground circuit) L04 (female) (5), circuit branch end and Min. 1 Mz
tance
ground
40-400 60 WA320, 320PZ-6

Contents of (5) Clearance lamp does not light up or go off.

trouble (6) Tail lamp does not light up or go off.
Defective switch, lamp, or wiring harness of the clearance lamp or tail lamp system.
Related When the headlamp and turn signal lamp light up.
information The input state (voltage) from the lamp switch (small lamp) to the machine monitor can be checked
with the monitoring function (Code: MONITOR PANEL 40200, SMALL LAMP).

If a specific lamp does not light up, its bulb may be broken or may
1 Broken bulb
have a defective contact. Check the bulb directly.
Defective fuses No. 10 and If the fuse is burn, the circuit probably has a grounding fault, etc.
2
No. 11 of fuse box (FS2) (See cause 5.)
Between (1) (2) 200 400 z
Defective small lamp relay, left
When small lamp relay (L117) is replaced with a relay of the same
type, if the condition becomes normal, the small lamp relay is defec-
tive.
Between (1) (2) 200 400 z
Defective small lamp relay,
right (L118) (Internal defect)
Possible When small lamp relay (L118) is replaced with a relay of the same
causes and type, if the condition becomes normal, the small lamp relay is defec-
standard value tive.
in normal state
Defective lamp switch L04 (male) Lamp switch Resistance

5
(Internal defect) OFF Min. 1 Mz
Between (1) (3) 1st position Max. 1 z
2nd position Max. 1 z
Max. 1 z
L117 (female) (2), L118 (female) (2) tance
Max. 1 z
Disconnection in wiring har-
ness a Carry out above 2 items when left side does not light.
6
(Disconnection or defective Wiring harness between fuse No. 11 of fuse Resis-
a Carry out above when right side does not light.
Max. 1 z
FLC1 (female) (A), R22 (female) (6) tance
Max. 1 z
FLC (female) (A), R23 (female) (6) tance
WA320, 320PZ-6 40-400 61


Resis-
L117 (female) (2), L118 (female) (2) and Min. 1 Mz
tance
ground
a Carry out above when lamp does not go off.
Resis-
tance
ground
Ground fault in wiring harness a Carry out above when left side does not go off.
7
(Contact with ground circuit) Wiring harness between fuse No. 11 of fuse
Resis-
tance
ground
Possible a Carry out above when right side does not light.
causes and Wiring harness between L117 (female) (5)
Resis-
standard value FLC1 (female) (A), R22 (female) (6) and Min. 1 Mz
tance
Resis-
FLC (female) (A), R23 (female) (6) and Min. 1 Mz
tance
ground
Headlamp switch is OFF
L117 (female) (2), L118 (female) (2), cir- Voltage Max. 1 V
Hot short in wiring harness cuit branch end and ground
8
(Contact with 5 V, 24V circuit) Wiring harness between L117 (female) (5)
FLC1 (female) (A), R22 (female) (6), cir- Voltage Max. 1 V
cuit branch end and ground
FLC (female) (A), R23 (female) (6), cir- Voltage Max. 1 V
40-400 62 WA320, 320PZ-6

WA320, 320PZ-6 40-400 63

SEN04197-01 E-15 Working lamp does not light up or go off
E-15 Working lamp does not light up or go off 1
Contents of
(1) Front working lamp does not light up or go off.
trouble
The switch, lamp, or wiring harness of the front working lamp system is defective
Related When the rear working lamp is normal
information If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
or may have a defective contact. Check the bulb directly.
2
Between (1) (2) 200 400 z
Defective front working lamp
When front working lamp relay (L122) is replaced with a relay of the
same type, if the condition becomes normal, the front working lamp
relay is defective.
causes and Front working lamp
standard value Defective front working lamp switch
in normal state 4
switch (Internal defect) ON Max. 1 z
Between (5) (6)
OFF Min. 1 Mz
Between (5), (6)
Constant Min. 1 Mz
ground
Max. 1 z
Max. 1 z
ness ground tance
5
box (FS2) L07 (female) (6), L122 (female) (3) tance
Max. 1 z
C04 (female) (1), C05 (female) (1) tance
Wiring harness between C04 (female) (2), Resis-
Max. 1 z
C05 (female) (2) ground tance
40-400 64 WA320, 320PZ-6

E-15 Working lamp does not light up or go off SEN04197-01

Min. 1 Mz
Ground fault in wiring harness Wiring harness between fuse No. 12 of fuse
6 Resis-
(Contact with ground circuit) box (FS2) L07 (female) (6), L122 (female) Min. 1 Mz
tance
(3) and ground
Possible
Resis-
standard value C04 (female) (1), C05 (female) (1), circuit Min. 1 Mz
tance
in normal state branch end and ground
Front working lamp switch turned off
Hot short in wiring harness Wiring harness between L07 (female) (5)
7 Voltage Max. 1 V
C04 (female) (1), C05 (female) (1), circuit Voltage Max. 1 V
WA320, 320PZ-6 40-400 65

Contents of
(2) Rear working lamp does not light up or go off.
trouble
The switch, lamp, or wiring harness of the rear working lamp system is defective.
Related When the front working lamp is normal
information If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.

If a specific working lamp does not light up, its bulb may be broken
1 Broken bulb
2
Between (1) (2) 200 400 z
Defective rear working lamp
When rear working lamp relay (L123) is replaced with a relay of the
same type, if the condition becomes normal, the rear working lamp
relay is defective.
causes and Rear working lamp
Defective rear working lamp L08 (male) Resistance
standard value switch
in normal state 4 switch
ON Max. 1 z
OFF Min. 1 Mz
Between (5), (6)
Constant Min. 1 Mz
ground
Max. 1 z
Max. 1 z
ness ground tance
5
box (FS2) L08 (female) (6), L123 (female) (3) tance
Max. 1 z
B01 (female) (1), B02 (female) (1) tance
Wiring harness between B01 (female) (2), Resis-
Max. 1 z
B02 (female) (2) ground tance
40-400 66 WA320, 320PZ-6


Max. 1 z
Ground fault in wiring harness Wiring harness between fuse No. 13 of fuse
6 Resis-
(Contact with ground circuit) box (FS2) L08 (female) (6), L123 (female) Max. 1 z
tance
(3) and ground
Possible
Resis-
standard value B01 (female) (1), B02 (female) (1), circuit Max. 1 z
tance
in normal state branch end and ground
Front working lamp switch turned off
Hot short in wiring harness Wiring harness between L08 (female) (5)
7 Voltage Max. 1 V
B01 (female) (1), B02 (female) (1), circuit Voltage Max. 1 V
WA320, 320PZ-6 40-400 67

40-400 68 WA320, 320PZ-6

WA320, 320PZ-6 40-400 69

SEN04197-01 E-16 Turn signal lamp and hazard lamp do not light up or go off
E-16 Turn signal lamp and hazard lamp do not light up or go off 1
Contents of
(1) Either of turn signal lamp and hazard lamp does not light up or go off.
trouble
The switch, lamp, or wiring harness of the turn signal lamp and hazard lamp system is defective.
The input state (ON/OFF) to the machine monitor from the turn signal lamp & hazard lamp switch
(right turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901,
Related
D-IN-12).
information
The input state (ON/OFF) to the machine monitor from the turn signal lamp & hazard lamp switch (left
turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901, D-
IN-13).

Defective No.2 and No.10 If the fuse is burn, the circuit probably has a grounding fault, etc.
1
fuses of fuse box (FS1) (See cause 8.)
Defective hazard relay (L125) Between (1) and (2) 200 400 z
2
(Internal defect) a Prepare with starting switch OFF, then turn starting switch ON
When hazard relay (L125) is replaced with a relay of the same type,
if the condition becomes normal, the hazard relay is defective.
Possible Between (5) and (6) 200 400 z
causes and
Defective hazard/turn signal (1), (2), (3), (4) (6) Min. 1 Mz
standard value 3
relay (L124)
in normal state a Prepare with starting switch OFF, then turn starting switch ON
When hazard/turn signal relay (L124) is replaced with a relay of the
same type, if the condition becomes normal, the hazard/turn signal
relay is defective.
L49 Voltage
Between (3) and (1) 20 30 V
Defective flasher unit 20 30 V and 0 V are indicated
4 Between (4) and (1)
(Internal defect) repeatedly.
Between (3), (4) and ground Min. 1 Mz
40-400 70 WA320, 320PZ-6

E-16 Turn signal lamp and hazard lamp do not light up or go off SEN04197-01

Max. 1 z
5
L04 (female) (6), L124 (female) (1), (3) tance
Max. 1 z
ground tance
Min. 1 Mz
Resis-
L04 (female) (6), L124 (female) (1), (3) and Min. 1 Mz
Ground fault in wiring harness tance
6 ground
Possible (Contact with ground circuit)
Resis-
standard value R23 (female) (1) FLC [left] (female) (C) and Min. 1 Mz
tance
Resis-
R22 (female) (1) FLC [right] (female) C and Min. 1 Mz
tance
ground
Voltage Max. 1 V
L04 (female) (6), L124 (female) (1), (3) and Voltage Max. 1 V
7 ground
R23 (female) (1) FLC [left] (female) (C) and Voltage Max. 1 V
ground
R22 (female) (1) FLC [right] (female) C and Voltage Max. 1 V
ground
WA320, 320PZ-6 40-400 71

Contents of
(2) Turn signal lamp does not light up or go off.
trouble
The switch, lamp, or wiring harness of the turn signal lamp system is defective.
When the hazard lamp lights up.
The input state (ON/OFF) to the machine monitor from the turn signal lamp and hazard lamp switch
Related (right turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901,
information D-IN-12).
The input state (ON/OFF) to the machine monitor from the turn signal lamp and hazard lamp switch
(left turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901,
D-IN-13).

If a specific turn signal lamp does not light up, its bulb may be bro-
1 Broken bulb
ken or may have a defective contact. Check the bulb directly.
Turn signal lamp
switch
Defective turn signal lamp Left Min. 1 Mz

2 Between (6) (7)
switch (Internal defect) Right Max. 1 z
Left Max. 1 z
Between (6) (8)
Right Min. 1 Mz
a Prepare with starting switch OFF, then check relay unit.
3 Defective hazard relay (L125) Resis-
Between L125 (female) (3) (6) Max. 1 z
tance
Wiring harness between fuse box FS1 No. Resis-
Possible Max. 1 z
causes and
in normal state
Max. 1 z
Disconnection in wiring har- R23 (female) (1), FLC (female) (C) tance
ness Wiring harness between L04 (female) (8) Resis-
4 Max. 1 z
(Disconnection or defective R22 (female) (1), FLC1 (female) (C) tance
contact in connector) Wiring harness between R22 (female) (4) Resis-
Max. 1 z
ground tance
Wiring harness between R23 (female) (4) Resis-
Max. 1 z
ground tance
Wiring harness between FLC (female) (B) Resis-
Max. 1 z
ground tance
Wiring harness between FLC1 (female) (B) Resis-
Max. 1 z
ground tance
Ground fault in wiring harness without turning starting switch ON.
5
(Contact with ground circuit) Wiring harness between fuse box FS1 No. Resis-
Min. 1 Mz
10 L125 (female) (6) and ground tance
40-400 72 WA320, 320PZ-6

Contents of
(3) Hazard lamp does not light up or go off.
trouble
Related The switch or lamp of the hazard lamp is defective.
information Carry out the following troubleshooting when the turn signal lamp flashes normally.

1
Defective hazard relay (L125) Between (1) (2) 200 400 z
2
When hazard relay (L125) is replaced with a relay of the same type,
if the condition becomes normal, the hazard relay is defective.
Between (1) (2) 200 400 z
Defective hazard/turn signal
When hazard/turn signal relay (L124) is replaced with a relay of the
same type, if the condition becomes normal, the hazard/turn signal
relay is defective.
Possible
causes and
standard value
Defective hazard lamp switch L06 (male) Hazard lamp switch Resistance
in normal state 4
(Internal defect)
ON Max. 1 z
Between (5) (6)
OFF Min. 1 Mz
Max. 1 z
box (FS1) L125 (female) (5) tance
Max. 1 z
Max. 1 z
Disconnection in wiring har- L06 (female) (5) tance
ness Resis-
5 Between L124 (female) (6) ground Max. 1 z
(Disconnection or defective tance
contact in connector) Resis-
Between L125 (female) (2) ground Max. 1 z
tance
Between L49 (female) (4) L124 (female) Resis-
Max. 1 z
(1), (3) tance
Between L124 (female) (2) FLC [right] (C), Resis-
Max. 1 z
R23 (1) tance
Between L124 (female) (4) FLC [left] (C), Resis-
Max. 1 z
R22 (1) tance
WA320, 320PZ-6 40-400 73


Min. 1 Mz
Ground fault in wiring harness box (FS1) L125 (female) (5) and ground tance
6
(Contact with ground circuit) Wiring harness between fuse No. 2 of fuse Resis-
Min. 1 Mz
Min. 1 Mz
L06 (female) (1), (5) and ground tance
Possible a Prepare with starting switch OFF, then turn starting switch ON
causes and and carry out troubleshooting.
standard value When hot short resulted on the wiring harnesses of the following
in normal state two circuits
R23 (female) (1), FLC (female) (C), cir- Voltage Max. 1 V
Hot short in wiring harness cuit branch end and ground
7
R22 (female) (1), FLCL (female) (C), cir- Voltage Max. 1 V
L125 (female) (1) L06 (female) (1), (5) and Voltage Max. 1 V
ground
40-400 74 WA320, 320PZ-6

WA320, 320PZ-6 40-400 75

SEN04197-01 E-17 Brake lamp does not light or it keeps lighting up
E-17 Brake lamp does not light or it keeps lighting up 1
Contents of
Brake lamp does not light or it keeps lighting up.
trouble
Related
The lamp or wiring harness of the brake lamp system is abnormal.
information

If a specific brake lamp does not light up, its bulb may be broken or
1 Broken bulb
Defective fuse No.11 of fuse If the fuse is burn, the circuit probably has a grounding fault, etc.
2
Between (1) (2) 200 400 z
Defective brake lamp relay
When brake lamp relay (L121) is replaced with a relay of the same
type, if the condition becomes normal, the brake lamp relay is defec-
tive.
L34 (male) Brake pedal Resistance
Defective brake lamp switch
4 Press Max. 1 z
Released Min. 1 Mz
Between (1), (2)
Possible Constant Min. 1 Mz
ground
causes and
in normal state without turning starting switch ON.
Resis-
box (FS1) L121 (female) (3), L34 Max. 1 z
tance
(female) (1)
ness Max. 1 z
(Disconnection or defective
ground tance
Max. 1 z
R22 (female) (5), R23 (female) (5) tance
Wiring harness between R22 (female) (4), Resis-
Max. 1 z
R23 (female) (4) ground tance
Resis-
box (FS1) L121 (female) (3), L34 Min. 1 Mz
tance
Ground fault in wiring harness (female) (1), circuit branch end and ground
6
Min. 1 Mz
Resis-
R22 (female) (5), R23 (female) (5) and Min. 1 Mz
tance
ground
40-400 76 WA320, 320PZ-6

E-17 Brake lamp does not light or it keeps lighting up SEN04197-01

Possible and carry out troubleshooting.
standard value Hot short in wiring harness Voltage Max. 1 V
7 L121 (female) (1) and ground
in normal state (Contact with 5 V, 24V circuit)
R22 (female) (5), R23 (female) (5) and Voltage Max. 1 V
ground
WA320, 320PZ-6 40-400 77

SEN04197-01 E-18 Backup lamp does not light or it keeps lighting up
E-18 Backup lamp does not light or it keeps lighting up 1
Contents of
Backup lamp does not light or it keeps lighting up.
trouble
The machine monitor monitors the primary circuit of the backup lamp relay for a trouble.
Related (If hot short occurs in the primary side of the back lamp relay, failure code [D160KY] is indicated.
information Carry out troubleshooting for it first.)
If another failure code is displayed, carry out troubleshooting for it first.

If a specific backup lamp does not light up, its bulb may be broken
1 Broken bulb
2
Between (1) (2) 200 400 z
Defective backup lamp 1 relay
When backup lamp 1 relay (L109) is replaced with a relay of the
same type, if the condition becomes normal, the backup lamp 1
relay is defective.
causes and without turning starting switch ON.
standard value L126 (male) Resistance
in normal state
Defective backup lamp 2 relay Between (1) (2) 200 400 z
4 (L126) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting.
relay is defective.
Between (1) (2) 200 400 z
Defective FR pressure select
When FR pressure select relay (L101) is replaced with a relay of the
same type, if the condition becomes normal, the FR pressure select
relay is defective.
40-400 78 WA320, 320PZ-6

E-18 Backup lamp does not light or it keeps lighting up SEN04197-01

Max. 1 z
Max. 1 z
Max. 1 z
Reference: Following 4 items are circuits for turning lamp ON with
directional lever in R position.
Max. 1 z
Max. 1 z
Max. 1 z
ground tance
ness
6 Reference: Following 4 items are circuits for turning lamp ON when
(Disconnection or defective
contact in connector) HST controller outputs signal to reverse solenoid.
Max. 1 z
Max. 1 z
R22 (female) (2) or R23 (female) (2) tance
Possible
causes and Wiring harness between HST (female) (20) Resis-
Max. 1 z
standard value L101 (female) (5) tance
in normal state Wiring harness between L101 (female) (6) Resis-
Max. 1 z
ground tance
Max. 1 z
ground tance
Max. 1 z
ground tance
Wiring harness between fuse box FS1 No. 5 Resis-
Max. 1 z
L24 (female) (4), (5) tance
Reference: If above wiring harness is disconnected, when directional
switch is set in R and lamp lights and then directional lever or direc-
tional switch is set in position other than R, lamp may not go off.
Resis-
box (FS2) L109 (female) (3), (1) circuit Min. 1 Mz
tance
Ground fault in wiring harness branch end and ground
7
(Contact with ground circuit) Wiring harness between L109 (female) (5)
Resis-
R22 (female) (2), R23 (female) (2), circuit Min. 1 Mz
tance
Min. 1 Mz
8
R22 (female) (2), R23 (female) (2), circuit Voltage Max. 1 V
WA320, 320PZ-6 40-400 79

SEN04197-01 E-18 Backup lamp does not light or it keeps lighting up
40-400 80 WA320, 320PZ-6

E-19 Backup alarm does not sound or it keeps sounding SEN04197-01
E-19 Backup alarm does not sound or it keeps sounding 1
Contents of
Backup alarm does not sound or it keeps sounding.
trouble
The machine monitor monitors the primary circuit of the backup lamp relay for a trouble.
Related (If hot short occurs in the primary side of the back lamp relay, failure code [D160KY] is indicated. In
information such case, give precedence to the troubleshooting of the failure indicated with the code.)
If another failure code is displayed, carry out troubleshooting for it first.

Defective backup alarm B03 Gear shift lever Voltage
1
(Internal defect)
R 20 30 V
Between (1) (2)
Other than R Max. 1 V
2
Between (1) (2) 200 400 z
Defective backup lamp 1 relay
Possible
relay is defective.
causes and
in normal state without turning starting switch ON.
Defective backup lamp 2 relay Between (1) (2) 200 400 z
4 (L126) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit) and carry out troubleshooting.
relay is defective.
Between (1) (2) 200 400 z
Defective FR pressure select
When FR pressure select relay (L101) is replaced with a relay of the
same type, if the condition becomes normal, the FR pressure select
relay is defective.
WA320, 320PZ-6 40-400 81

SEN04197-01 E-19 Backup alarm does not sound or it keeps sounding

Max. 1 z
Max. 1 z
Max. 1 z
Reference: Following 4 items are circuits for turning backup alarm
ON with directional lever in R position.
Max. 1 z
Max. 1 z
Max. 1 z
Max. 1 z
ness ground tance
6
(Disconnection or defective Reference: Following 4 items are circuits for turning backup alarm
contact in connector) ON when HST controller outputs signal to reverse solenoid.
Max. 1 z
Possible Max. 1 z
causes and
in normal state
Max. 1 z
ground tance
Wiring harness between B03 (female) (2) Resis-
Max. 1 z
ground tance
Wiring harness between fuse box FS1 No. 5 Resis-
Max. 1 z
L24 (female) (4), (5) tance
Reference: If above wiring harness is disconnected, when directional
switch is set in R and backup alarm turned ON and then directional
lever or directional switch is set in position other than R, backup alarm
may not go OFF.
Resis-
box (FS2) L109 (female) (3), (1) circuit Min. 1 Mz
tance
7
(Contact with ground circuit) Wiring harness between L109 (female) (5)
Resis-
R22 (female) (2), R23 (female) (2), circuit Min. 1 Mz
tance
Min. 1 Mz
8
R22 (female) (2), R23 (female) (2), circuit Voltage Max. 1 V
40-400 82 WA320, 320PZ-6

E-19 Backup alarm does not sound or it keeps sounding SEN04197-01
WA320, 320PZ-6 40-400 83

SEN04197-01 E-20 Horn does not sound or it keeps sounding
E-20 Horn does not sound or it keeps sounding 1
Contents of
Horn does not sound or it keeps sounding.
trouble
Related

information

1
Defective horn relay (L116) Between (1) (2) 200 400 z
2
When horn relay (L116) is replaced with a relay of the same type, if
the condition becomes normal, the horn relay is defective.
Defective L13 horn switch L13 (male) Horn switch Resistance
3
(Internal defect)
ON Max. 1 z
Between (1) ground
OFF Min. 1 Mz
Possible and carry out troubleshooting. (Disconnect connector and mea-
causes and sure on female side)
standard value F01, F02 Horn switch Voltage
in normal state
Defective horn ON Max. 1 V
4 Between F01 (1) (2)
(Internal defect) OFF 20 30 V
ON Max. 1 V
Between F02 (1) (2)
OFF 20 30 V
a If horn does not sound normally under above condition, it is
defective.
Max. 1 z
Max. 1 z
5
F01 (female) (1), F02 (female) (1) tance
Max. 1 z
F02 (female) (2) ground tance
Wiring harness between steering wheel horn Resis-
Max. 1 z
switch ground tance
40-400 84 WA320, 320PZ-6

E-20 Horn does not sound or it keeps sounding SEN04197-01

Resis-
box (FS2) L116 (female) (1), (3), circuit Min. 1 Mz
tance
6
Possible (Contact with ground circuit) Wiring harness between L116 (female) (5)
Resis-
causes and F01 (female) (1), F02 (female) (1), circuit Min. 1 Mz
tance
standard value branch end and ground
in normal state Wiring harness between L116 (female) (2) Resis-
Min. 1 Mz
and carry out troubleshooting while not pressing horn switch.
7 Wiring harness between L116 (female) (5)
F01 (female) (1) or F02 (female) (1) and Voltage Max. 1 V
ground
WA320, 320PZ-6 40-400 85

SEN04197-01 E-21 Alarm buzzer does not sound or it keeps sounding
E-21 Alarm buzzer does not sound or it keeps sounding 1
Contents of
Alarm buzzer does not sound or it keeps sounding.
trouble
Disconnection or ground fault in alarm buzzer output circuit
Related The output state (ON/OFF) from the alarm buzzer to the machine monitor can be checked with the
information monitoring function (Code: MONITOR PANEL 40952, D-OUT-0).
If failure code is indicated, carry out troubleshooting for it first.

1
box FS1 (See cause 4.)
Remove the buzzer then connect +24 V to L46 (male) (1) and
Defective alarm buzzer GND to L46 (male) (2).
2
(Internal defect) Alarm buzzer is
Alarm buzzer sounds
normal
Defective alarm
Alarm buzzer does not sound
buzzer
causes and Disconnection in wiring har- without turning starting switch ON.
standard value ness Wiring harness between fuse No. 5 of fuse Resis-
in normal state 3 Max. 1 z
(Disconnection or defective box FS1 L46 (female) (1) tance
Max. 1 z
Ground fault in wiring harness Resis- Min.
4 box FS1 L46 (female) (1), circuit branch
(Contact with ground circuit) tance 1 Mz
end and ground
Wiring harness between L46 (female) (2) Resis- Min.
L24 (female) (14) and ground tance 1 Mz
When above 1 4 are normal, failure on the machine monitor can
be suspected.
40-400 86 WA320, 320PZ-6

E-21 Alarm buzzer does not sound or it keeps sounding SEN04197-01
WA320, 320PZ-6 40-400 87

SEN04197-01 E-22 Air conditioner does not operate or stop
E-22 Air conditioner does not operate or stop 1
Contents of
Air conditioner does not operate or stop.
trouble
The following is troubleshooting applicable only to the power supply and GND circuit between the air
Related
conditioner and operator's cab. For troubleshooting of the air conditioner unit, see the Shop Manual
information
for the air conditioner.

Defective No.1 and No.2 fuses
of fuse box (FS2) or defective
If the fuse is burn, the circuit probably has a grounding fault, etc.
1 5A and 15A fuses of the main
(See cause 2.)
circuit in the air conditioner
unit.
When fuse No. 1 of fuse box (FS2) is blown
box A 5A fuse of air conditioner main cir- Resis- Min.
cuit, 15A fuse in the air conditioner and tance 1 Mz
ground
When fuse No. 1 of fuse box (FS2) is broken
Wiring harness between fuse No. 1 of fuse Resis- Min.
box A compressor clutch relay and ground tance 1 Mz
Wiring harness between compressor clutch Resis- Min.
Grounding fault in power relay E10 (female) (2) and ground tance 1 Mz
2 supply wiring harness
(Contact with ground circuit) a Prepare with starting switch OFF, then carry out troubleshooting
causes and When 5A fuse of the air conditioner unit main circuit is broken
standard value Wiring harness between 5A fuse of air condi-
in normal state tioner unit main circuit C48 (female) (7), Resis- Min.
pressure switch, blower OFF relay primary tance 1 Mz
side and ground
When 15A fuse of the air conditioner unit is broken
Wiring harness between 15A fuse of air con- Resis- Min.
ditioner unit blower OFF relay and ground tance 1 Mz
Wiring harness between blower OFF relay Resis- Min.
blower motor and ground tance 1 Mz
C48 Starting switch Voltage
Defective A/C control panel ON 20 30 V
Between (7) and (1)
power supply and disconnec- OFF Max. 1 V
3 tion of GND wring harness a Prepare with starting switch OFF, then carry out troubleshooting
(disconnection or defective without turning starting switch ON.
Max. 1 z
box (FS2) C48 (female) (7) tance
Wiring harness between C48 (female) (1) Resis-
Max. 1 z
ground tance
40-400 88 WA320, 320PZ-6

E-22 Air conditioner does not operate or stop SEN04197-01

Blower OFF relay,
Starting switch Voltage
pressure switch
Blower OFF relay ON 20 30 V
(15A fuse line) and
ground OFF Max. 1 V
Blower OFF relay (5A ON 20 30 V

fuse line of main cir-
cuit) and ground OFF Max. 1 V
Pressure switch ON 20 30 V
Possible
Disconnection in wiring har- (5A fuse line of main
causes and OFF Max. 1 V
ness of relay power supply circuit) and ground
standard value 4
in normal state (Disconnection or defective a Prepare with starting switch OFF, then carry out troubleshooting
contact in connector) without turning starting switch ON.
Resis-
box (FS2) blower OFF relay (on the 15A Max. 1 z
tance
fuse line)
Resis-
box (FS2) blower OFF relay (on the 5A fuse Max. 1 z
tance
line of main circuit)
Resis-
box (FS2) pressure switch (on the 5A fuse Max. 1 z
tance
line of main circuit)
Wiring harness between pressure switch Resis-
Max. 1 z
compressor clutch relay tance
WA320, 320PZ-6 40-400 89

SEN04197-01 E-22 Air conditioner does not operate or stop
40-400 90 WA320, 320PZ-6

E-22 Air conditioner does not operate or stop SEN04197-01
WA320, 320PZ-6 40-400 91

SEN04197-01 E-23 The KOMTRAX system does not work properly
E-23 The KOMTRAX system does not work properly 1
Trouble The KOMTRAX system does not work properly.

If the KOMTRAX system administrator asks you to check whether any defect occurs in the machine
Related
system, carry out the following troubleshooting.
information
A defect in the KOMTRAX system, if any, does not appear especially as a defective phenomenon.
Cause Standard value in normal state/Remarks on troubleshooting

L80 Signal Voltage
1 Defective power supply Between (39), (40) Constant power
20 30 V
(37) and (38) supply
a Turn the starting switch ON, then start engine and carry out trou-
bleshooting.
LED (1) Normal state
LED-C1 ON
Defective starting switch a Prepare with starting switch OFF, then start engine and carry out
2 ACC signal and alternator R troubleshooting.
signal L80 Signal Voltage
Between (36) and
Starting switch ACC 20 30 V
(37), (38)
Between (28) (37),
Alternator R 20 30 V
(38)
a Turn the starting switch ON, then carry out troubleshooting.
During cranking: Blinking
LED-C3
Other than above: OFF
Possible Defective starting switch C and carry out troubleshooting.
3
causes and signal L80 Signal Voltage
standard value
in normal state Between (10) and (9) S-NET 69V
During cranking:
Between (27) and 20 30 V
Starting switch C
(37), (38) Other than above:
Max. 1 V
a Turn the starting switch ON, and carry out troubleshooting.
LED-C4 ON
Defective CAN connection
4
L80 (female) Signal Resistance
Between (7) and (8) CAN 40 80 z
5 Number of unsent mails LED (7) Normal state
7 segments 09
Defective GPS positioning Dot ON
6
status
One or more minute may be taken until GPS positioning is com-
pleted after the starting switch was turned ON even in an outdoor
service area.
40-400 92 WA320, 320PZ-6

E-23 The KOMTRAX system does not work properly SEN04197-01
LED display L80 connector
LED lamps for CPU

1. LED-C1 (State of R or ACC signal)
2. LED-C2 (Starting output state)
3. LED-C3 (State of C signal)
4. LED-C4 (CAN state)
7 segment and dot displays for CPU
7. 7 segments (Number of unsent mails)
8. Dot (GPS positioning state)
WA320, 320PZ-6 40-400 93

SEN04197-01

2009 KOMATSU
All Rights Reserved
40-400 94
SEN04198-01
WA320-6
WA320PZ-6
WA320-6 70001 and up

500 Troubleshooting of hydraulic and

mechanical system (H-mode)
Method of using troubleshooting chart............................................................................................................ 3
Failure code and cause table .......................................................................................................................... 6
H-1 The machine does not start...................................................................................................................... 8
H-2 The travel speed is slow........................................................................................................................... 9
H-3 The traction force is weak ...................................................................................................................... 10
H-4 Engine stalls when traveling or engine speed drops excessively............................................................11
H-5 Shift range is not shifted......................................................................................................................... 12
H-6 The steering wheel does not turn........................................................................................................... 13
H-7 The steering wheel is heavy................................................................................................................... 14
H-8 Steering wheel shakes or jerks .............................................................................................................. 15
H-9 Machine deviates naturally to one side when traveling.......................................................................... 15
H-10 The brake does not work or does not work well................................................................................... 16
H-11 The brake is not released or is dragged ............................................................................................... 17
H-12 The lift arm does not rise or lower ........................................................................................................ 18
H-13 The lift arm moves slowly or the lift arm rising force is insufficient....................................................... 19
H-14 When rising, the lift arm comes to move slowly at specific height ....................................................... 20
H-15 The lift arm cylinder cannot hold down the bucket (The bucket rises in the air) .................................. 20
H-16 Hydraulic drifts of the lift arm occur often ............................................................................................. 20
H-17 The lift arm wobbles during operation .................................................................................................. 20
H-18 When the control lever is switched from HOLD to RAISE, the lift arm falls temporarily .................. 21
H-19 The bucket does not tilt back ............................................................................................................... 22
WA320, 320PZ-6 40-500 1

500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN04198-01
H-20 The bucket moves slowly or the tilting-back force is insufficient .......................................................... 23
H-21 The bucket comes to operate slowly in the midst of tilting-back .......................................................... 24
H-22 The bucket cylinder cannot hold down the bucket ............................................................................... 24
H-23 Hydraulic drifts of the bucket occur often ............................................................................................. 24
H-24 The bucket wobbles during travel with load (The work equipment valve is set to HOLD) ................. 24
H-25 When the control lever is switched from HOLD to TILT, the bucket falls temporarily ...................... 25
H-26 The control levers of the lift arm and bucket do not move smoothly and heavy................................... 25
H-27 The ECSS does not operate and machine pitches and bounces......................................................... 26
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) ................ 27
40-500 2 WA320, 320PZ-6

Method of using troubleshooting chart SEN04198-01
Method of using troubleshooting chart 1
This troubleshooting chart determines the location from the problem occurring on the machine and catego-
rizes the problem under one of the main components, such as the steering system or work equipment
hydraulic system. Use the following procedure to carry out accurate troubleshooting swiftly.
Step 1. Ask operator questions Step 3. Method of reading matrix

q The questions to ask the operator are given 1. Operate the machine when carrying out trou-
under the problem. If the answer to the ques- bleshooting of the items in the Diagnosis col-
tion matches the content given, the cause umn. If any problems occur as the result of the
given after the arrow is the probable troubleshooting, put a check against the item.
cause.Keeping the content of the questions in a When carrying out the troubleshooting,
mind, read the matrix and proceed with Step 2 check the easier items first. It is not neces-
and Step 3 to pinpoint the correct cause. sary to follow the number order.
[Example]
Example: Steering does not turn
Ask the operator and check the following points. Remedys
No.
q Did the problem suddenly start? Diagnosis
o Related equipment broken Steering does not turn in both directions (left
1
q Was the steering wheel heavy before? and right)
o Wear of related parts, defective seal Steering turns only in one direction (left or
2
right)
Step 2. Checks before troubleshooting Steering is heavy when turned in both direc-
q Before measuring the oil pressure or starting 3
tions (left and right)
the troubleshooting, confirm the checks before Steering wheel is heavy in one direction (left
starting items, check for leakage of oil, or for 4
or right)
loose bolts. This will prevent wasting time
5 Work equipment moves
when troubleshooting. The items given under
Checks before troubleshooting are checks
that are particularly important to make about 2. Find the matching cause in the Cause column.
the condition of the machine before starting the In the same way as in Step 2), if a problem is
actual troubleshooting. found, the Q marks on the same line for the
troubleshooting item are the causes. (In Diag-
Example: Checks before starting troubleshoot- nosis item 2 in the same diagram below the
ing cause is (c) or (e).)
q Is oil level and type of oil in hydraulic tank cor- When there is one Q mark:
rect? Carry out troubleshooting for the other items
q Is there any oil leakage from steering valve or marked with Q in the same Cause column to
demand valve? check if the problem occurs, then make
q Is steering linkage adjusted properly? repairs.
When there are two Q marks:
Go to Step 3) to narrow down the cause.
WA320, 320PZ-6 40-500 3

SEN04198-01 Method of using troubleshooting chart
3. Operate the machine and carry out trouble- 6. Repeat the operation in Steps 3, 4, and 5 until
shooting of the items not checked in Step 1. the cause is narrowed down to 1 item (1 com-
Operate the machine in the same way as in mon item).
Step 1, and if any problem occurs, put a check a If cause items are 2 or more, continue until
against the item. (In Troubleshooting item 5 in number of items becomes minimum.
the diagram below, the problem was re-
enacted.) 7. Remedy
After narrowing down the common causes,
4. Find the matching cause in the Cause column. take the action given in the remedy line.
In the same way as in Step 2), if a problem is Marks and remedies in remedy line
found, the Q marks on the same line for the : Replace E: Repair A: Adjust C: Clean
troubleshooting item are the causes. (In Diag-
nosis item 5 in the diagram below the cause is
(b) or (e).)
5. Narrow down the causes.

Of the causes found in Step 2) and Step 4),
there are common items (Q marks on the line
for each Diagnosis item and in the same
Cause column as each other) that have
causes common with the problem items found
in the troubleshooting in Step 1) and Step 3).
a The items that are not common (items that
do not have Q marks in the same cause
common as each other) are probably not
the cause, so they can be eliminated. (The
causes for Diagnosis item 2 in the dia-
gram below are (c) or (e), and the causes
in Diagnosis item 5 are (b) or (e), so
Cause (e) is the common cause.)
40-500 4 WA320, 320PZ-6

Method of using troubleshooting chart SEN04198-01
WA320, 320PZ-6 40-500 5

SEN04198-01 Failure code and cause table
Failure code and cause table 1
Part causing problem HST pump HST HST

motor 2 motor 1
Pump body (Charge pump end)

Pump body (Piston pump end)
Angle stopper control solenoid

Mode selector solenoid valve
Angle stopper solenoid valve

High pressure cut-off valve
Directional solenoid valve

High pressure relief valve
Low pressure relief valve
Inching valve linkage

(Charge relief valve)
Inching valve
Motor body
Motor body
DA valve
Damper
(SOL a)
(SOL b)
valve
Failure Code
Does not travel forward or in reverse Q Q Q Q Q Q Q Q Q Q Q

Does not travel forward (reverse is normal) Q Q
The machine does not start at reverse (Forward is normal) Q Q
Speed is slow in both forward and reverse Q Q Q Q Q Q Q Q Q Q Q
HST related
The travel speed is slow at forward (Reverse is normal) Q Q

The travel speed is slow at reverse (Forward is normal) Q Q
The traction force is weak in both forward and reverse Q Q Q Q Q Q
The traction force is weak at forward (Reverse is normal) Q
The traction force is weak at reverse (Forward is normal) Q
Engine stalls when traveling or engine speed drops excessively Q Q Q
Shift range is not shifted Q Q
Brake Steering wheel
The steering wheel does not turn

The steering wheel is heavy
There is play in steering wheel or excessive shock
Machine deviates naturally to one side when traveling
The brake does not work or does not work well
The brake is not released or is dragged
The lift arm does not rise or lower Q Q
The lift arm moves slowly or the lift arm rising force is insufficient Q
When the lift arm is rising, the lift arm comes to move slowly at
specific height
The lift arm cylinder cannot be hold down the bucket
(The bucket rises in the air)
Hydraulic drift of the lift arm occurs often
Work equipment system
The lift arm wobbles during operation

When the control lever is switched from HOLD to RAISE, the lift
arm falls temporarily
The bucket does not tilt back Q Q
The bucket moves slowly or the tilting-back force is insufficient Q
The bucket comes to operate slowly in the midst of tilting-back
The bucket cylinder cannot be hold down to bucket
Hydraulic drift of the bucket occurs often
The bucket wobbles during travel with load
(The work equipment valve is set to HOLD)
When the control lever is switched from HOLD to TILT, the bucket
falls temporarily
The control levers of the lift arm and bucket do not move smoothly
and heavy
(if equipped)
ECSS does not operate but pitches and bounces

ECSS
ECSS does not move at all
Fan revolution is abnormal (Fan sound/vibration is abnormally large

Hydraulic
or engine overheats)
fan
Fan always revolves in reverse
40-500 6 WA320, 320PZ-6

Clutch solenoid
Q Q
Q Q
Clutch
Q Q Q
Q Q Q
Transfer
Q
Q
Q
Q
Q
Q
Q
Work equipment and steering pump
Q
Brake pump
Q
Orbit-roll
WA320, 320PZ-6
Q
Q
Q
Q
Q
Priority valve
Q Q Q
Q Q Q
Relief valve
Failure code and cause table
Steering valve
Safety valve
Q
Q
Q
Steering cylinder
Q Q Q
Tire inflation pressure
Accumulator charge valve
Brake valve
Slack adjuster
Brake disc and plate
Axle
Q Q Q
Brake piston
Q Q Q Q Q Q
Wheel brake linkage
Q
Q
Q
Main relief valve
Q Q
Q Q
Q
Q
Q Q
Lift arm spool
Q
Bucket spool
Q Q
Q Q
Q
Q Q
Q
Suction and safety valve
control valve
Work equipment
Suction valve
Q
Q
Q Q
Q
Q
Q
Lift arm cylinder
Q
Q
Q
Q
Q
Bucket cylinder
Q
Q
Q
Lift arm PPC valve
Q
Q
Q Q
Q
Bucket PPC valve
Q
Bypass valve
2-way restrictor valve
Q Q
Cushion valve
ECSS solenoid valve
Q Q
Q
Accumulator
Fan pump
Q
Fan motor
Q Q Q
Charge valve
40-500
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-28
H-27
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
7
SEN04198-01
SEN04198-01 H-1 The machine does not start
H-1 The machine does not start 1
Ask the operator about the following: Cause
HST motor 2
HST motor 1
q Has the machine come not start suddenly?
HST pump
Damper
o Breakage of HST pump and motor related
Others
equipment
q Was there any problem of not traveling before?
o Internal wear of HST pump and motor related
a b c d e f g h i j k l m n o
equipment, defective seal
Low pressure relief valve (Charge relief valve)

Inspection before diagnosis
q Are the oil level in the hydraulic tank and the oil type
appropriate?
q Is inching valve linkage properly adjusted?

q Is the any external oil leak found around the hydraulic
piping, pump and motor?


Clutch solenoid
Inching valve
Motor body
Motor body
DA valve
Transfer
Damper
Clutch
E E E E E E E E E E E E E E E
Remedy
No. X X X X X X X X X X X X X X X
Diagnosis A
1 Does not travel forward or in reverse Q Q Q Q Q Q Q Q Q Q Q Q Q Q
2 Does not travel forward (reverse is normal) Q Q
3 Does not start at reverse (Forward is normal) Q Q
Does not travel forward or in reverse, motor makes sound of Q Q Q
4
rotation
40-500 8 WA320, 320PZ-6

H-2 The travel speed is slow SEN04198-01
H-2 The travel speed is slow 1

q Did the travel speed suddenly become HST pump HST motor 2
HST
Others
slower? motor 1
o Breakage of HST pump and motor a b c d e f g h i j k l m n o
related equipment
q Was there any problem of travel speed
Low pressure relief valve (Charge relief valve)

becoming slower before?
o Internal wear of HST pump and
Mode selector solenoid valve (SOL a)
Angle stopper solenoid valve (SOL b)

motor related equipment, defective
Angle stopper control solenoid valve

seal


q Are the oil level in the hydraulic tank and

the oil type appropriate?
q Is the inching valve linkage adjusting
Clutch solenoid
Inching valve
appropriate?
Motor body
Motor body
q Is the any external oil leak found around
DA valve
Clutch
the hydraulic piping, pump and motor?
E E E E E E E E E E E E E E E
Remedy X X X X X X X X X X X X X X X
No.
Diagnosis A
1 Travel speed is slow in both forward and reverse Q Q Q Q Q Q Q Q Q Q Q Q Q
The travel speed is slow at forward (Reverse is nor-
2 Q Q
mal)
The travel speed is slow at reverse (Forward is nor-
3 Q Q
mal)
Maximum travel speed in both forward and reverse Q
4
is approx. 4 km/h
Maximum travel speed in both forward and reverse Q
5
is approx. 18 km/h
Abnormal sound comes from motor in both forward
6 Q Q
and reverse when travel speed is 10 km/h or more
WA320, 320PZ-6 40-500 9

SEN04198-01 H-3 The traction force is weak
H-3 The traction force is weak 1
a When the travel speed is slow, carry out troubleshooting for Cause
H-2 first. HST HST HST
Others
pump motor 2 motor 1
a b c d e f g h i j
Inclination control solenoid valve


Clutch solenoid
Inching valve
Motor body
Motor body
Transfer
Clutch
E E E E E E E E E E
Remedy
No. X X X X X X X X X X
Diagnosis A
1 The traction force is weak in both forward and reverse Q Q Q Q Q Q Q Q Q
2 The traction force is weak at forward (Reverse is normal) Q
3 The traction force is weak at reverse (Forward is normal) Q
The traction force is weak in both forward and reverse, but maxi- Q Q Q
4
mum travel speed is reached the line.
40-500 10 WA320, 320PZ-6

H-4 Engine stalls when traveling or engine speed drops excessively SEN04198-01
H-4 Engine stalls when traveling or engine speed drops excessively 1

q Was there any problem before? HST HST
Others
o Dirt in HST pump, motor related equipment pump motor 2
a b c
Inclination stopper solenoid valve (SOL b)

q Is the any external oil leak found around the hydraulic piping, pump and
motor?

DA valve
E E E
Remedy
No. X X X
Diagnosis
1 Engine stalls when traveling or engine speed drops excessively Q Q Q

2 Machine moves when the directional lever is at F or R and engine is at Lo Q
WA320, 320PZ-6 40-500 11

SEN04198-01 H-5 Shift range is not shifted
H-5 Shift range is not shifted 1
a If the speed range switch and the monitor display do not match, check Cause
the electrical wiring. HST HST
a When the travel speed is slow, carry out troubleshooting for H-2 first. Others
motor 2 motor 1
a b c d
Inclination stopper solenoid valve (SOL b)
Clutch solenoid
Clutch
E E E E
Remedy
No. X X X X
Diagnosis
1 Shift range is not shifted Q Q Q Q
40-500 12 WA320, 320PZ-6

H-6 The steering wheel does not turn SEN04198-01
H-6 The steering wheel does not turn 1

q Did the problem suddenly start? Hydraulic
Others
o Breakage of steering related equipment pump
q Was there previously any symptom, such as heavy steering? a b c d e f
o Internal wear of steering related equipment, defective seal
Internal defective steering cylinder (Defective piston seal)

Defective hydraulic pump or PTO
Steering pump and switch pump
q Are the oil level in the hydraulic tank and the oil type appropriate?
q Has the lock bar been removed from frame?
Priority valve
Emergency steering valve (*1)

2-way restrictor valve
Relief valve
Orbit-roll
Steering
Spool
E E E E
Remedy
No. X X X X X X X
Diagnosis
1 Steering wheel does not turn in both directions (left and right) Q Q Q Q Q Q
2 In condition in Item 1, movement of work equipment is abnormal Q
3 In condition in Item 1, movement of work equipment is normal Q
4 Steering wheel turns only in one direction (left or right) Q Q Q
5 Steering wheel is heavy and does not turn Q Q Q Q
6 Oil pressure of steering circuit is low or there is no pressure Q
7 Emergency steering does not function in both directions (left and right) Q
a There is a close connection between the steering circuit and work equipment circuit, so if any abnormal-
ity is felt in the steering, check the operation of the work equipment also.
a If the steering pump is abnormal (broken), check the priority valve at the same time.
*1. This warning is given only when the emergency steering is installed.
WA320, 320PZ-6 40-500 13

SEN04198-01 H-7 The steering wheel is heavy
H-7 The steering wheel is heavy 1

q Did the problem suddenly start? Hydraulic
Valve Others
o Breakage of steering related equipment pump
q Was there previously any symptom, such as heavy steering? a b c d e f
o Internal wear of steering related equipment, defective
The steering pump is defective The hydraulic pump is defective

seal
Clogging of hydraulic oil return filter, defective bypass valve

Internal defective steering cylinder (Defective piston seal)
q Are the oil level in the hydraulic tank and the oil type appropri-
ate?
q Is there any abnormality in Orbit-roll, steering column linkage?
Priority valve
q Is the any external oil leak found around the hydraulic piping,
valve and cylinder?
q Is there any gouging of center hinge pin bearing and steering
cylinder pin, bushing?
q Is the tire inflation pressure correct?
Check for abnormalities
Orbit-roll internal defect

q Measure operating effort of steering wheel and time taken to
Clogging of oil cooler

turn steering, and check standard judgement value table to
see if there is any abnormality.
Relief valve
Spool
E E E E E E E
Remedy
No. X X X X X X X
Diagnosis A C C
1 Steering wheel is heavy when turned in both directions (left and right) Q Q Q Q Q
2 Steering wheel is heavy when turned in one direction (left and right) Q Q
Steering wheel is heavy particularly when engine is running at low Q Q Q Q
3
speed
4 Lift arm lifting speed is slow when engine is running at full speed Q Q
5 Steering wheel is heavy and there is jerking Q Q
6 Hydraulic oil overheats Q Q Q
7 Oil pressure of steering circuit is low or there is no pressure Q Q
8 Pressure rises in return piping of steering cylinder Q
40-500 14 WA320, 320PZ-6

H-8 Steering wheel shakes or jerks SEN04198-01
H-8 Steering wheel shakes or jerks 1
Checks before troubleshooting Cause

q Is the hydraulic oil level correct? Is the type of oil correct? Valves Cylinder Valves
q Is there any play in the center hinge pin bearing or steering cylinder pin or a b c d
bushing?
Defect inside steering cylinder (inside surface of cylinder, piston seal, nut, bolt)
q Is there any variation in the tire inflation pressure?
q Is the steering wheel play correct?
Check for abnormalities

q Operate at a safe place and check how the steering wheel shakes and under
what conditions.
a In cases where the steering wheel is heavy but does not shake, go to H-7 The
steering wheel is heavy.
Defective 2-way restrictor valve
Defective cushion valve

Defect inside Orbit-roll
E E E
Remedy
No. X X X X
Diagnosis
1 Chassis shakes when traveling on rough road surface Q Q Q

2 Shakes when steering is suddenly turned during operation or travel Q Q Q
3 Chassis shakes when accelerating during travel operations Q Q Q
4 Chassis shakes when engine is started Q
5 Excessive shock when steering wheel is turned back Q
H-9 Machine deviates naturally to one side when traveling 1
Causes: Defective steering

q Defective operation of safety valve
q Oil leakage inside steering cylinder
q Variation in tire inflation pressure
WA320, 320PZ-6 40-500 15

SEN04198-01 H-10 The brake does not work or does not work well
H-10 The brake does not work or does not work well 1

q Has the brake come not to work suddenly? a b c d e f g h i j k
o Breakage of brake equipment
Defective seal of accumulator piston, insufficient gas pressure

q Has the brake come not to work gradually?
Metal contact due to complete wear of brake lining in axle

o Wear of lining and disc, defective seal
Defective operation of accumulator charge valve

q Is the oil level in the hydraulic tank appropriate?
q Is the play of brake pedal appropriate?
Wear or abnormality of brake lining in axle

Defective operation of brake piston in axle
q Oil leak from brake tube and connector, deformation of
tube.
q Tire air pressure and state of tire tread.
Defective brake pump (For charge)

Defective brake piston seal in axle
Check abnormality
Mixing of air in brake circuit

q Measure the braking force and check referring to the stan-
Defect inside brake valve

Defective slack adjuster
dard value table if the brake does not work practically.
Defective brake linkage

E E E E E E E
Remedy
No. X X X X X X X X X A
Diagnosis
1 When the brake pedal is stepped on, only a little resistance is felt Q Q Q Q Q
2 When the brake pedal is stepped on, a strong resistance is felt Q Q
When the brake works, an abnormal noise occurs from the axle Q Q
3
brake
When the four wheels are jacked up, the axle is placed on a table
4 and the brake is applied at the first forward speed, only a specific Q Q Q Q
wheel rotates
An airflow is observed in bleeding air from brake circuit, and the Q
5
brake returns to normal after the bleeding
6 Brake oil leaks abnormally from the axle during inspection Q
7 Much metal powders are mixed in the axle oil Q
The brake pedal leg-power and stroke are normal, but the brake Q Q Q Q Q Q Q Q Q
8
does not work well
9 The brake does not work often when the engine is stopped Q Q Q Q Q Q
10 The accumulator is not charged, and a buzzer sounds Q Q Q
11 The brake works after some time lag Q Q Q
40-500 16 WA320, 320PZ-6

H-11 The brake is not released or is dragged SEN04198-01
H-11 The brake is not released or is dragged 1

q Has the brake pedal returned completely? a b c d
q Is the parking brake released completely?
Wear or abnormality of brake lining in axle

Defective operation of brake piston in axle
Check abnormality
Defective brake piston seal in axle

q Abnormal heat of brake.
q Does the machine travel smoothly inertia on a level ground?
Defective slack adjuster

Remedy E E E E
No. X X X X
Diagnosis
1 The brake pedal is released, but the brake is still applied Q Q Q Q
When the brake pedal is released, oil is drained from the air bleeder, the circuit oil pressure Q Q
2
drops and the brake is released
When the four wheels are jacked up, the axle is placed on a table, the engine is stopped, the
3 Q Q Q
parking brake is released and the tires are rotated by hand but a specific tire hardly rotates
WA320, 320PZ-6 40-500 17

SEN04198-01 H-12 The lift arm does not rise or lower
H-12 The lift arm does not rise or lower 1

q Has the lift arm come not to work suddenly? Work
Priority HST PPC
o Seizure or breakage of each equipment Tank to Pump
valve pump valve
equip- Cylinder
Did any abnormal noise occur at the time ment valve
(And where)? a b c d e f g h i j
q Was there the phenomenon that the lift arm
Clogging of pump suction port or mixing of much air in oil

worked slowly?
o Wear of parts or deformation of spring
Breakage inside valve body (Lift arm spool)

q Is the oil level in the hydraulic tank appropriate?
q Is the stroke of the lift arm control lever appro-
Defective operation of main relief valve
Damage of lift arm cylinder piston seal

priate?
Defective low-pressure relief valve

q Is the engine speed appropriate?
Defective work equipment pump

Defective HST charge pump
Defective operation of spool

Defective steering pump
Remedy C E E E E E E
No. E X X X X X X X X X
Diagnosis
The bucket cannot operate and the lift arm cannot Q Q Q Q Q Q Q Q
1
rise
2 The bucket operates but the lift arm cannot rise Q Q
The lift arm can rise without load but cannot rise
3 Q Q Q Q
when loaded
4 The hydraulic pump causes an abnormal noise Q Q Q Q
5 Large hydraulic drift of lift arm cylinder Q Q
When the engine is at full throttle, the steering opera- Q Q
6
tion is heavy and slow
40-500 18 WA320, 320PZ-6

H-13 The lift arm moves slowly or the lift arm rising force is insufficient SEN04198-01
H-13 The lift arm moves slowly or the lift arm rising force is insufficient 1
Inspection before diagnosis Cause
q Is the stroke of the lift arm control lever appropri- Tank to Priority HST PPC Work equipment
Cylinder
ate? Pump valve pump valve valve
a b c d e f g h
Check of abnormality
Defective operation or improper adjustment of main relief valve

q Rising force and speed problem are closely
related, and this problem occurs as insufficient ris-

ing speed at first. Measure the lift arm rising speed
when the lift arm is loaded and make sure referring
Wear or breakage inside valve body (Lift arm spool)

Defective work equipment pump and steering pump
to the criterion table that the speed is abnormal.
Damage of lift arm cylinder piston seal

Defective low-pressure relief valve

Remedy C E E E E A E
No. E X X X X X X X
Diagnosis
The bucket tilting force and speed are abnormal, and Q Q Q Q Q
1
the lift arm rising speed is slow
The bucket tilting force and speed are normal, and the
2 Q Q Q
lift arm rising speed is slow
When the oil temperature rises in item 1, the lift arm Q Q
3
speed becomes very slow
4 The hydraulic pump causes an abnormal noise Q Q
5 Large hydraulic drift of lift arm cylinder Q Q
The relief oil pressure from the relief valve of the work Q
6
equipment valves is low
The relief oil pressure from the relief valve of the work
7 Q
equipment valves is too high
WA320, 320PZ-6 40-500 19

SEN04198-01 H-14 When rising, the lift arm comes to move slowly at specific height
H-14 When rising, the lift arm comes to move slowly at specific height 1

q Deformation of lift arm cylinder in appearance
Cause
q Expansion of lift arm cylinder tube or damage inside
a For other abnormal phenomena during lift arm rise, see H-13. The lift arm moves slowly or the lift arm
rising force is insufficient.
H-15 The lift arm cylinder cannot hold down the bucket (The bucket
rises in the air) 1
See H-13. The lift arm moves slowly or the lift arm rising force is insufficient.

q Is the stroke of the lift arm control lever appropriate?
Cause
q Defective seat of suction valve on the lift arm cylinder rod side of work equipment valve
q Oil leak from lift arm cylinder piston seal
H-16 Hydraulic drifts of the lift arm occur often 1
Ask the operator about the following:

q Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to occur often gradually? o Wear of parts

q Is the lift arm spool at the neutral position? o The spool detent is defective
Diagnosis and Cause

q Does any leaking noise occur inside the lift arm cylinder when hydraulic drift is measured? o The cylin-
der packing is defective
H-17 The lift arm wobbles during operation 1
The bucket and the lift arm moves up and down as the topography goes in digging or leveling with the lift arm
control lever in the HOLD position.
Diagnosis and Cause

Check at first the hydraulic drift and if the lift arm cylinder can lift the machine
1. When the hydraulic drift is more than the standard value, see H-16. Hydraulic drifts of the lift arm occur
often.
2. When the lift arm cylinder cannot lift the machine, see H-15. The lift arm cylinder cannot hold down the
bucket.
3. When the lift arm cylinder comes to enable to lift the machine after the lift arm is operated several times
with the normal hydraulic drift and after the lift arm cylinder operates to full stroke o The cause is vac-
uum generated inside the cylinder
a Frequent hydraulic drifts o The suction valve on the lift arm cylinder rod side is defective
40-500 20 WA320, 320PZ-6

H-18 When the control lever is switched from HOLD to RAISE, the lift arm falls temporarily SEN04198-01
H-18 When the control lever is switched from HOLD to RAISE, the
lift arm falls temporarily 1
Check of Phenomenon
q When the control lever is switched from HOLD to RAISE gradually at low idle of the engine, the lift
arm falls temporarily due to its own weight. When the control lever is completely set to RAISE, the lift
arm returns to normal.
Cause
q Improper adhesion of lift arm spool check valve of the work equipment valve
WA320, 320PZ-6 40-500 21

SEN04198-01 H-19 The bucket does not tilt back
H-19 The bucket does not tilt back 1

q Has the bucket come not to work suddenly Priority HST PPC Work equip- Cylin-
Tank to Pump
o Seizure or breakage of each equip- valve pump valve ment valve der
ment a b c d e f g h i j
Did any abnormal noise occur at the
The HST charge pump (which is used as PPC pump, too) is defective
time (And where)?
q Was there the phenomenon that the bucket
worked slowly?
o Wear of parts or deformation of

spring

q Is the stroke of the bucket and lift arm con-
trol levers appropriate?
Breakage inside valve body (Bucket spool)

The low-pressure relief valve is defective
Defective operation of main relief valve
Damage of bucket cylinder piston seal

The hydraulic pump is defective
The steering pump is defective
The spool is defective
Remedy C E E E E A
No. E X X X X X X X X
Diagnosis
The lift arm cannot operate and the bucket can-
1 Q Q Q Q Q Q Q
not tilt back
The bucket can lift the machine but cannot tilt
2 back, or the lift arm operates but the bucket can- Q Q Q
not tilt back
The bucket can tilt back without load but cannot Q
3 Q Q
in digging or scooping up
4 The hydraulic pump causes an abnormal noise Q Q Q
5 Large hydraulic drift of bucket cylinder Q Q
When the engine is at full throttle, the steering
6 Q Q
operation is heavy and slow
40-500 22 WA320, 320PZ-6

H-20 The bucket moves slowly or the tilting-back force is insufficient SEN04198-01
H-20 The bucket moves slowly or the tilting-back force is insufficient 1
Inspection before diagnosis Cause

q Is the stroke of the bucket control lever Tank to Priority HST PPC
Work equipment valve Cylinder
appropriate? Pump valve pump valve
q Seizure of work equipment linkage a b c d e f g h i
bushing (Does any abnormal noise
Defective operation or improper adjustment of main relief valve

occur?)

The hydraulic pump and the steering pump are defective
Check of abnormality
Defective operation of safety valve (With suction valve)

q Make sure in an actual operation that
Wear or breakage inside valve body (Bucket spool)

the tilting-back force is insufficient.
Defective operation of low-pressure relief valve

q Measure the operating speed of the
bucket, and make sure referring to the
criterion value table that the speed is
Damage of bucket cylinder piston seal

abnormal
on bucket cylinder bottom side

Remedy C E E E E A E
No. E X X X X X X X X
Diagnosis
The lift arm rising force and speed are
1 abnormal, and the bucket tilting force and Q Q Q Q Q
speed are abnormal
The lift arm rising force and speed are nor-
2 mal, and the bucket tilting force and speed Q Q Q Q
are abnormal
When the oil temperature rises in item 1, the
3 Q Q
bucket speed becomes worse
The hydraulic pump is causing an abnormal Q Q
4
noise
5 Large hydraulic drift of bucket cylinder Q Q Q
The relief oil pressure from the relief valve of Q Q Q
6
the work equipment valves is low
The relief oil pressure from the relief valve of
7 Q
the work equipment valves is too high
WA320, 320PZ-6 40-500 23

SEN04198-01 H-21 The bucket comes to operate slowly in the midst of tilting-back
H-21 The bucket comes to operate slowly in the midst of tilting-back 1

q Deformation of bucket cylinder in appearance
Cause
q Expansion of bucket cylinder tube or damage inside
q For other abnormal phenomena during bucket operation, see H-20. The bucket moves slowly or the tilt-
ing-back force is insufficient.
H-22 The bucket cylinder cannot hold down the bucket 1
See H-20. The bucket moves slowly or the tilting-back force is insufficient.

q Is the stroke of the bucket control lever appropriate?
Cause
q Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
q Oil leak from bucket cylinder piston seal
H-23 Hydraulic drifts of the bucket occur often 1
Ask the operator about the following:

q Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
q Have hydraulic drifts come to occur often gradually? o Wear of parts

q Is the bucket lever (PPC valve) at the neutral position? o Seizure of link bushing or the spool detent is
defective
Check of Abnormality
q Refer to the criterion value table and check if the hydraulic drift of the bucket occurs often practically
Cause
q Oil leak in bucket cylinder
q Improper adhesion of safety valve (With suction valve) on the bottom side
q Improper oil tight of bucket spool
H-24 The bucket wobbles during travel with load

(The work equipment valve is set to HOLD) 1

q Pin of work equipment linkage and play of bushing (Is any abnormal noise heard?)
Cause
q Defective seal of bucket cylinder piston
q Defective operation of safety valve (With suction valve) on bucket cylinder rod side. For other abnormal
phenomena, refer to diagnoses for relevant abnormal phenomena.
40-500 24 WA320, 320PZ-6

H-25 When the control lever is switched from HOLD to TILT, the bucket falls temporarily SEN04198-01
H-25 When the control lever is switched from HOLD to TILT, the
bucket falls temporarily 1
Check of Phenomenon
q When the control lever is switched from HOLD to TILT gradually at low idle of the engine, the bucket
falls temporarily due to its own weight. When the control lever is completely set to TILT, the bucket
returns to normal.
Cause
q Improper adhesion of bucket spool check valve of the work equipment valve
H-26 The control levers of the lift arm and bucket do not move smoothly
and heavy 1
Check of Abnormality Cause

q Refer to the criterion value table and check if the lever operating efforts are large practically. PPC
valve
a

Remedy C
No. E
Diagnosis
1 Becomes heavy in some places during operation regardless of oil pressure and oil temperature Q
2 Becomes heavy overall during operation regardless of oil pressure and oil temperature Q
WA320, 320PZ-6 40-500 25

SEN04198-01 H-27 The ECSS does not operate and machine pitches and bounces
H-27 The ECSS does not operate and machine pitches and bounces 1
Check the following points with the operator. Cause

q Did the machine starts pitching and bouncing sud- Solenoid
Accumulator Controller Sensor
denly? valve
o Breakage of related device a b c d
Did abnormal sound come out when the machine
Gas leakage from accumulator or defective seal

started pitching and bouncing? From what part did
the abnormal sound come out?
q Did the machine starts pitching and bouncing gradu-
ally?
o Wear of related device or defective seal
Defective travel speed sensor

Malfunction of solenoid valve
Check before troubleshooting
q Check that the hydraulic tank is filled with oil of a
Malfunction of controller
proper type up to a proper level.
q Check that the ECSS switch is set properly.
Remedy X X X
No. X
Troubleshooting
Travel speed to start operation of ECSS (6 km/h) changes
1 Q Q
largely
2 ECSS does not work while machine is loaded Q Q
3 ECSS does not work while machine is empty Q Q
Lift arm lowers more than 30 cm at maximum when ECSS Q
4
operated while machine is loaded
5 ECSS does not work at all Q Q Q Q
40-500 26 WA320, 320PZ-6

H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats) SEN04198-01
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally

large or engine overheats) 1
Check the following with the operator. Cause

q Did the fan start making the abnormal sound sud- Tank to Charge
Fan motor Others
denly? Pump valve
o Damage of the devices related to the fan and a b c d e f g h i j k
fan motor
q Did the engine overheat after the fan had started
making the abnormal sound?
o Internal wear of the devices related to the fan
pump and fan motor, lowering of sealing per-
Clogging or sucked air on pump suction side

formance or dirt
Check for abnormality
Seized forward-reverse selector valve

q Measure the fan speed to check for abnormality.
Malfunction of suction safety valve

Malfunction of EPC solenoid valve
Seized brake circuit selector spool
Lowering of engine performance

Seized ON/OFF solenoid valve
Check before troubleshooting
q Check the level and type of the oil in the hydraulic
Malfunction of relief valve
Malfunction of controller
tank.
q Check the hydraulic hoses, pump and motor for oil
Defective fan motor

Defective fan pump
leakage.
q Check the fan for damage.
(Note): If Lowering of engine performance is judged, go to the

troubleshooting for the engine system (S mode).
Remedy C Note
No. E E E E E E E
Troubleshooting X X X X X X X X X
1 Fan speed is low (in fan 100% mode) Q Q Q Q Q Q
2 Fan hunts Q Q Q Q Q
3 Fan does not revolve Q Q Q Q
4 Fan always revolves in reverse Q Q Q
5 Fan does not revolve in reverse Q Q Q
WA320, 320PZ-6 40-500 27

SEN04198-01

2009 KOMATSU
All Rights Reserved
40-500 28
SEN04199-01
WA320-6
WA320PZ-6
WA320-6 70001 and up

600 Troubleshooting of engine (S-mode)

Method of using troubleshooting charts .......................................................................................................... 2
S-1 Starting performance is poor .................................................................................................................... 6
S-2 Engine does not start ............................................................................................................................... 8
S-3 Engine does not pick up smoothly...........................................................................................................11
S-4 Engine stops during operations .............................................................................................................. 12
S-5 Engine does not rotate smoothly ............................................................................................................ 13
S-6 Engine lacks output (or lacks power) ..................................................................................................... 14
S-7 Exhaust smoke is black (incomplete combustion).................................................................................. 15
S-8 Oil consumption is excessive (or exhaust smoke is blue) ...................................................................... 16
S-9 Oil becomes contaminated quickly ......................................................................................................... 17
S-10 Fuel consumption is excessive............................................................................................................. 18
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) ................................................... 19
S-12 Oil pressure drops ................................................................................................................................ 20
S-13 Oil level rises (Entry of coolant or fuel)................................................................................................. 21
S-14 Coolant temperature becomes too high (overheating) ......................................................................... 22
S-15 Abnormal noise is made....................................................................................................................... 23
S-16 Vibration is excessive ........................................................................................................................... 24
WA320, 320PZ-6 40-600 1

SEN04199-01 Method of using troubleshooting charts
Method of using troubleshooting charts 1
The troubleshooting chart consists of the ques-

tions, check items, causes, and troubleshoot-
ing blocks.
The questions and check items are used to pinpoint
high probability causes by simple inspection or
from phenomena without using troubleshooting
tools.
Next, troubleshooting tools or direct inspection are
applied to check the narrowed causes in order from
the most probable one to make final confirmation
according to the troubleshooting procedure.
[Questions]:
Items to be drawn from the user or operator.
They correspond to A and B in the chart on the
right.
The items in A are basic ones.
The items in B can be drawn from the user or
operator, depending on their level.
[Check items]:
Items to be simply checked by the serviceman
to narrow down causes.
They correspond to C in the chart on the right.
[Causes]:
Items to be narrowed from the questions and
check items.
The serviceman narrows down the probable
causes from A, B, and C.
[Troubleshooting]:
Items to finally verify whether the narrowed
down causes are undoubtedly the real causes
using the troubleshooting tools and direct
inspections.
40-600 2 WA320, 320PZ-6

Method of using troubleshooting charts SEN04199-01
Items listed in the [Questions] and [Check items] and related to the [Causes] are marked with E, Q, or w.
E : Causes to be referred to for questions and check items
Q : Causes related to questions and check items
w : Causes highly probable among ones marked with Q
a When narrowing the causes, apply the items marked with w before those marked with Q.
When narrowing the causes, do not apply the items marked with E. (If no items have other marks and
the causes cannot be narrowed, however, you may apply them.)
WA320, 320PZ-6 40-600 3

SEN04199-01 Method of using troubleshooting charts
<Example of troubleshooting> Exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. 3 symptoms have
causal relationship with this problem: [Color of exhaust gas gradually became black], [Power was lost gradu-
ally], and [Air cleaner clogging caution lamp is flashing].
40-600 4 WA320, 320PZ-6

Method of using troubleshooting charts SEN04199-01
If we look from these 3 symptoms to find the causes, we find that there is a relationship with 5 causes. Let us
explain here the method of using this causal relationship to pinpoint the most probable cause.
WA320, 320PZ-6 40-600 5

SEN04199-01 S-1 Starting performance is poor
S-1 Starting performance is poor 1
General causes why starting performance is poor Causes

q Defective electrical system
Leaking or clogged fuel piping, entry of air

Clogged air breather hole of fuel tank cap
Defective contact of valve and valve seat
Defective alternator (generator section)

q Insufficient supply of fuel
Defective alternator (regulator section)

q Insufficient intake of air
Stuck, seized supply pump plunger
Defective intake air heater system
Defective or deteriorated battery

q Improper selection of fuel
a The common rail fuel injection system (CRI) controls the
Clogged air cleaner element
Clogged fuel filter, element

Worn piston ring, cylinder
fuel injection timing electrically. Accordingly, even if the
starting operation is carried out, the engine may not start
until the crankshaft revolves 2 turns at maximum. This phe-
Defective injector
nomenon does not indicate a trouble, however.
Confirm recent repair history

Degree of use of machine Operated for long period E E E
Became worse gradually Q w w Q
Starting performance
Engine starts easily when warm w w
Questions
Non-specified fuel is being used Q Q Q

Replacement of filters has not been carried out according to Operation and
Maintenance Manual w w Q Q
Oil must be added more frequently w

When engine is preheated or when temperature is low, preheating monitor does not
indicate normally w
During operation, charge level monitor indicates abnormal charge w w

Dust indicator is red w
Air breather hole of fuel tank cap is clogged w
Fuel is leaking from fuel piping w Q
When priming pump is operated, it makes no reaction or it is heavy w Q
Starting motor cranks engine slowly w
If air bleeding plug of fuel filter is removed, fuel does not
While engine is cranked flow out w
with starting motor,
Much fuel returns from the injector w
Check items
When exhaust manifold is touched immediately after starting engine, temperature of

w
some cylinders is low
Engine does not pick up smoothly and combustion is irregular Q Q w
There is hunting from engine (rotation is irregular) Q w Q
Blow-by gas is excessive w
Inspect air cleaner directly q

When compression pressure is measured, it is found to be low q q
When air is bled from fuel system, air comes out q
Inspect fuel filter, strainer directly q
Troubleshooting
Carry out troubleshooting according to No-pressure feed by supply pump (*1) in display
q
of code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
q
change
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Is voltage 20 30 V between alternator terminal B and terminal E with Yes q

engine at low idle? No q
When specific gravity of electrolyte and voltage of battery are measured, they are low q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
40-600 6 WA320, 320PZ-6

S-1 Starting performance is poor SEN04199-01
*1: Failure codes [CA559] and [CA2249] in the display of code
WA320, 320PZ-6 40-600 7

SEN04199-01 S-2 Engine does not start
S-2 Engine does not start 1
a) Engine does not turn Causes
Defective connection of battery terminal
Defective starting motor (motor section)

General causes why engine does not turn
q Seized parts inside engine
o See S-4 Engine stops during operations
Defective or deteriorated battery
Defective steering circuit wiring

q Defective electrical system
q Problem in drive devices on applicable machine side
Broken flywheel ring gear
Defective starting switch

o Carry out troubleshooting for devices on applicable machine
Defective battery relay
Defective safety relay

Questions
Degree of use of machine Operated for long period E E
Condition of horn when Horn does not sound Q Q w

starting switch is turned ON Horn volume is low w
Battery electrolyte is low w
Battery terminal is loose w
When starting switch is turned ON, there is no operating sound from battery relay Q w
When starting switch is turned to START, starting pinion does not move out Q Q w
Check items
Speed of rotation is low w

When starting switch is Makes grating noise w w
turned to START, starting
pinion moves out, but Soon disengages again w
Makes rattling noise and does not turn Q Q Q
Inspect flywheel ring gear directly q
Carry out troubleshooting in E-mode

There is not voltage (20 30 V) between battery relay terminal B and q
terminal E
Troubleshooting
When terminal B and terminal C of starting switch are connected, q

engine starts
Turn starting switch OFF, When terminal B and terminal C at safety relay outlet are connected,
connect cord, and carry out q
engine starts
troubleshooting at ON
Even if terminal B and terminal C at safety relay outlet are connected,
q
engine does not start
When terminal at safety switch and terminal B at starting motor are
q
connected, engine starts
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
40-600 8 WA320, 320PZ-6

S-2 Engine does not start SEN04199-01
b) Engine turns but no exhaust smoke comes out Causes
Defective operation of overflow valve (Does not close)

General causes why engine turns but no exhaust smoke comes
out
q Fuel is not being supplied
q Supply of fuel is extremely small

q Improper selection of fuel (particularly in winter)
Defective common rail pressure limiter

Seized, abnormally worn feed pump

Defective supply pump IMV (IMA)
Clogged fuel filter element
Broken supply pump shaft

Insufficient fuel in tank
Defective fuel injector

Use of improper fuel
Questions
Exhaust smoke suddenly stopped coming out (when starting again) w Q w w E

Fuel other than specified one is used w
Replacement of filters has not been carried out according to Operation and w E Q
Maintenance Manual
When fuel tank is inspected, it is found to be empty w
Air breather hole of fuel tank cap is clogged Q w
Rust and water are found when fuel tank is drained Q E E E
When fuel filter is removed, there is not fuel in it w w
w
Check items
Fuel is leaking from fuel piping

While engine is cranked with flow out Q Q w Q
starting motor,
If spill hose from injector is disconnected, little fuel spills Q w w w Q

Inspect fuel filter directly q
Troubleshooting
Inspect feed pump directly q

Carry out troubleshooting according to No-pressure feed by supply pump (*1) in
display of code q q
Carry out troubleshooting according to Abnormality in supply pump IMV (IMA) (*2) in
q
display of code
Inspect pressure relief valve directly q
Fuel flows out when pressure limiter return piping is disconnected q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Add
Remedy

WA320, 320PZ-6 40-600 9

SEN04199-01 S-2 Engine does not start
c) Exhaust smoke comes out but engine does not start Causes
Worn dynamic valve system (Valve, rocker lever, etc.)

(fuel is being injected)
Defective coolant temperature sensor, wiring harness

General causes why exhaust smoke comes out but engine does
not start
Leaking or clogged fuel system, entry of air

q Lack of rotating force due to defective electrical system

Defective intake air heater system

Clogged injector, defective spray
Defective, deteriorated battery

Clogging of fuel filter

Use of improper fuel
Suddenly failed to start w w Q
Questions
Non-specified fuel is being used Q Q

w w
Maintenance Manual
When engine is preheated or when temperature is low, preheating monitor does not w
indicate normally
Air breather hole of fuel tank cap is clogged Q
Rust and water are found when fuel tank is drained w
Fuel is leaking from fuel piping w
Starting motor cranks engine slowly w
w
Check items
When engine is cranked, abnormal sound is generated around cylinder head

While engine is cranked with flow out Q w
starting motor,
If spill hose from injector is disconnected, little fuel spills w

Inspect dynamic valve system directly q
When compression pressure is measured, it is found to be low q
Troubleshooting

Inspect fuel filter directly q
Carry out troubleshooting according to No-pressure feed by supply pump (*1) in display
q
of code
Coolant temperature gauge does not indicate normally q
When starting switch is turned to HEAT, intake air heater mount does not become warm q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Remedy
*1: Failure code [CA559] and [CA2249] in the display of code
40-600 10 WA320, 320PZ-6

S-3 Engine does not pick up smoothly SEN04199-01
S-3 Engine does not pick up smoothly 1
General causes why engine does not pick up smoothly Causes

Seized turbocharger, interference of turbocharger

q Defective condition of fuel injection

q Controller is controlling in derate mode

Clogged injector, defective spray
(limiting injection rate (output) because of an error in electrical system)

Improper valve clearance

Degree of use of machine Operated for long period E E E E
Questions
Engine pick-up suddenly became worse w Q Q Q

Non-specified fuel is being used w w w
Replacement of filters has not been carried out according to Operation and Maintenance w w
Manual
Rust and water are found when fuel tank is drained w
When exhaust manifold is touched immediately after starting engine, temperature of some Q w
cylinders is low
Blue under light load w
Color of exhaust gas is
w Q w w
Check items
Black
When engine is cranked, abnormal sound is generated around cylinder head w
When engine is cranked, interference sound is generated around turbocharger w
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w
There is hunting from engine (rotation is irregular) Q Q Q

q
Troubleshooting
Inspect valve clearance directly

When turbocharger is rotated by hand, it is found to be heavy q
Carry out troubleshooting according to No-pressure feed by supply pump (*1) in display of q
code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change q
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Remedy
WA320, 320PZ-6 40-600 11

SEN04199-01 S-4 Engine stops during operations
S-4 Engine stops during operations 1
General causes why engine stops during operations Causes

Internal parts of engine seized
Broken dynamic valve system (valve, rocker arm, etc.)

q
Broken auxiliary equipment (pump, compressor, etc.)

q There is overheating
Defective engine controller power supply wiring

q Problem in hydraulic pump

Broken, seized piston, connecting rod

Broken, seized crankshaft bearing
Clogging feed pump gauze filter
Defective starting switch wiring

Clogging of fuel filter, strainer
Leaking, clogged fuel piping
Broken, seized feed pump

Broken supply pump shaft
Defective hydraulic pump

Broken, seized gear train
Abnormal noise was heard and engine
stopped suddenly w w w w Q w Q w w
w Q Q Q Q
Questions
Condition when engine Engine overheated and stopped

stopped
Engine stopped slowly w Q Q Q Q
There was hunting and engine stopped w Q Q Q Q
Non-specified fuel is being used Q Q Q Q
Replacement of filters has not been carried out according to Operation
and Maintenance Manual w w
Fuel level monitor indicates low level w

Rust and water are found when fuel tank is drained w w
Metal particles are found when oil pan is drained w w Q Q
Check items
Does not turn at all w w

When engine is cranked by Turns in opposite direction w
hand Moves by amount of gear backlash w w
Supply pump shaft does not turn w
Engine turns, but stops when load is applied to machine w

Carry out troubleshooting in H-mode
Inspect piston, connecting rod directly q

Inspect crankshaft bearing directly q
Inspect gear train directly q
Troubleshooting

Inspect feed pump gauze filter directly q
Inspect feed pump directly q
Carry out troubleshooting according to No-pressure feed by supply
q q
pump (*1) in display of code
Engine rotates when pump auxiliary equipment (pump, compressor, etc.)
q
is removed
Check controller power supply wiring q
Check starting switch wiring q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Clean
Clean
Clean
Add
Remedy
40-600 12 WA320, 320PZ-6

S-5 Engine does not rotate smoothly SEN04199-01
S-5 Engine does not rotate smoothly 1
General causes why engine does not rotate smoothly Causes

q Air in fuel system
Clogged injector, defective spray (dirt in injector)

q Defective speed sensor (Error at degree that it is not indicated)
Defective Ne speed sensor, wiring harness

Defective G speed sensor, wiring harness


Degree of use of machine Operated for long period E
Q Q
Questions
Occurs at a certain speed range

Occurs at low idle Q Q Q Q Q
Hunting
Occurs even when speed is raised Q Q Q
Occurs on slopes w
Replacement of filters has not been carried out according to Operation and Maintenance Manual w
Check items
Rust and water are found when fuel tank is drained Q


Troubleshooting

Carry out troubleshooting according to Abnormality in Ne speed sensor (*1) in display of code q
Carry out troubleshooting according to Abnormality in Bkup speed sensor (*2) in display of code q
Replace
Replace
Replace
Replace
Replace
Clean
Add
Remedy
*1: Failure code [CA689] in the display of code

*2: Failure code [CA778] in the display of code
WA320, 320PZ-6 40-600 13

SEN04199-01 S-6 Engine lacks output (or lacks power)
S-6 Engine lacks output (or lacks power) 1
General causes why engine lacks output Causes

Clogged injector, defective spray (dirt in injector)
Defective boost pressure sensor, wiring harness

Defective installation of boost pressure sensor
Defective drive of injector (signal, solenoid)



Air leakage from air intake piping

o See S-14 Coolant temperature becomes too
Leaking, clogged fuel piping

high (Overheating)

Clogged fuel spill piping


(limiting injection rate (output) because of an
error in electrical system)
(air leakage)
Suddenly Q w Q Q Q Q
Questions
Power was lost

Gradually Q Q Q Q Q Q
Non-specified fuel is being used Q Q Q
w w
Maintenance Manual
Oil must be added more frequently Q Q
Dust indicator is red w w
Air breather hole of fuel tank cap is clogged w w
Output becomes insufficient after short stop of operation w
Black w w
w w
some cylinders is low
w
Check items
When engine is cranked, interference sound is generated around turbocharger

High idle speed is too high Q
High idle speed under no load is normal, but speed suddenly drops when load is applied Q w Q Q
Engine does not pick up smoothly and combustion is irregular w w Q Q w
There is hunting from engine (rotation is irregular) Q Q Q Q Q
Blow-by gas is excessive w w

Inspect air intake piping directly q
When boost pressure is measured, it is found to be low q q q
Inspect valve clearance directly q
Troubleshooting
Inspect fuel piping q

Inspect spill port check valve directly q
Carry out troubleshooting according to No-pressure feed by supply pump (*1) in
q
display of code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Inspect boost pressure sensor mount directly q
Carry out troubleshooting according to Abnormality in boost pressure sensor (*2)
q
in display of code
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Adjust
Clean
Clean
Remedy

40-600 14 WA320, 320PZ-6

S-7 Exhaust smoke is black (incomplete combustion) SEN04199-01
S-7 Exhaust smoke is black (incomplete combustion) 1
General causes why exhaust smoke is black Causes
Leakage of air between turbocharger and cylinder head



o See S-14 Coolant temperature becomes too high
(Overheating)

Improper fuel injection pressure

(limiting injection rate (output) because of an error in

Crushed, clogged muffler
Abnormally worn injector

Improper injection timing
electrical system)
Clogged, seized injector

Suddenly became black w w Q Q Q
w Q Q
Questions
Color of exhaust gas is Gradually became black

Suddenly w Q Q Q
Power was lost
Gradually Q Q Q Q
Muffler is crushed w
Air leaks between turbocharger and cylinder head, clamp is loosened w
Engine is operated in low-temperature mode at normal temperature Q Q Q
When exhaust manifold is touched immediately after starting engine, temperature of some Q w
cylinders is low
Check items

Torque converter stall speed or pump relief speed is high (Fuel is injected excessively) Q
Exhaust noise is abnormal Q w Q
Engine does not pick up smoothly and combustion is irregular Q Q Q Q Q w
Much fuel returns from the injector w

When turbocharger is rotated by hand, it is fount to be heavy q
Troubleshooting
Inspect valve clearance directly q

When muffler is removed, exhaust sound improves q
Carry out troubleshooting according to No-pressure feed by supply pump (*1) in display of
code q q
Carry out troubleshooting according to Abnormality in coolant temperature sensor (*2) in
q
display of code
Confirm with monitoring function q q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Remedy

WA320, 320PZ-6 40-600 15

SEN04199-01 S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-8 Oil consumption is excessive (or exhaust smoke is blue) 1
General causes why oil consumption is excessive Causes

q Abnormal consumption of oil
Turbocharger
Oil leakage from oil pan, cylinder head, etc.

Worn, damaged valve (stem, guide, seal)
q Long-time operation of engine at low idle or high idle
(Do not run engine at idle for more than 20 minutes
Dust sucked in from intake system

continuously)
Clogged breather, breather hose

q External leakage of oil
Oil leakage from oil drain plug

Worn, damaged rear oil seal
q Wear of parts in lubrication system
Oil leakage from oil cooler
Oil leakage from oil piping

Worn seal at turbine end
Worn seal at blower end
Oil leakage from oil filter

Broken piston ring
Broken oil cooler

E E E E
Questions
Degree of use of machine Operated for long period

Oil consumption suddenly increased w Q
Oil must be added more frequently w Q
Oil becomes contaminated quickly Q Q w
Outside of engine is dirty with oil w w w w w
There are loose piping clamps in intake system w
Inside of turbocharger intake outlet pipe is dirty with oil w
Inside of turbocharger exhaust outlet pipe is dirty with oil Q w
Check items
There is oil in coolant w

Oil level in damper chamber is high w
Exhaust smoke is blue under light load w w
Excessive Q Q w w
Amount of blow-by gas
None w
When intake manifold is removed, dust is found inside q

When intake manifold is removed, inside is found to be dirty abnormally q
Troubleshooting
Excessive play of turbocharger shaft q q

Check breather and breather hose directly q
Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q q
There is external leakage of oil from engine q q q q
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
40-600 16 WA320, 320PZ-6

S-9 Oil becomes contaminated quickly SEN04199-01
S-9 Oil becomes contaminated quickly 1
General causes why oil becomes contaminated quickly Causes

q Entry of exhaust gas into oil due to internal wear
Clogged turbocharger lubrication drain tube

Defective seal at turbocharger turbine end
q Clogging of lubrication passage
q Use of improper fuel
q Use of improper oil
Clogged breather, breather hose

q Operation under excessive load
Defective oil filter safety valve

Worn valve, valve guide
Exhaust smoke is bad

Clogged oil cooler
Clogged oil filter
Questions

Metal particles are found when oil filter is drained Q Q w
Inside of exhaust pipe is dirty with oil w
Engine oil temperature rises quickly w
Check items

Black w
Excessive Q Q w Q
Amount of blow-by gas
None w
Excessive play of turbocharger shaft q

Troubleshooting
Check breather and breather hose directly q
See S-7
Inspect oil cooler directly q
Inspect oil filter directly q
Spring of oil filter safety valve is hitched or broken q
Inspect turbocharger lubrication drain tube directly q
Replace
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy
WA320, 320PZ-6 40-600 17

SEN04199-01 S-10 Fuel consumption is excessive
S-10 Fuel consumption is excessive 1
General causes why fuel consumption is excessive Causes

q Leakage of fuel

q Defective condition of fuel injection (fuel pressure, injection timing)
q Excessive injection of fuel
Fuel leakage from fuel filter, piping, etc.

Defective fuel supply pump oil seal
Defective common rail pressure

Fuel leakage inside head cover
Defective supply pump plunger
Defective operation of injector

Defective spray by injector
Improper injection timing

E E E
Questions

More than for other machines of same model Q Q Q Q
Condition of fuel Gradually increased Q Q
consumption
Suddenly increased Q Q
There is external leakage of fuel from engine w
Combustion is irregular w
Engine oil level rises and oil smells of diesel fuel w w
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low w
Check items
Low idle speed is high Q

HST stall speed is high Q
Black Q Q Q Q
White Q
Remove head cover and inspect directly q

Inspect fuel supply pump oil seal directly q
Troubleshooting
Carry out troubleshooting according to No-pressure feed by supply pump (*1) in display of code q
Much fuel returns from the injector q
Carry out troubleshooting according to Abnormality in coolant temperature sensor (*2) in display
of code q
Confirm with monitoring function q q

Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy

40-600 18 WA320, 320PZ-6

S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) SEN04199-01
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant Causes
q Internal leakage in lubrication system
Broken cylinder head, head gasket

q Internal leakage in cooling system
Broken oil cooler core, O-ring
Broken hydraulic oil cooler or

Cracks inside cylinder block
Holes caused by pitting
power train oil cooler

E E
Questions

Suddenly rose Q Q Q
Oil level
Gradually rose Q Q
Hard water is being used as coolant Q Q
Oil level has risen and oil is milky Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
Check items
Hydraulic oil or power train oil on applicable machine side is milky w

When hydraulic oil or power train oil is drained, water is found w
Pressure-tightness test of cylinder head shows there is leakage q

shooting
Trouble-
Inspect cylinder block directly q q Check directly

Pressure-tightness test of oil cooler shows there is leakage q
Replace
Replace
Replace
Replace
Remedy
WA320, 320PZ-6 40-600 19

SEN04199-01 S-12 Oil pressure drops
S-12 Oil pressure drops 1
General causes why oil pressure drops Causes

q Leakage, clogging, wear of lubrication system
Leaking, crushed, clogged hydraulic piping

Defective oil level sensor, wiring harness
q Defective oil pressure control
q Selection of oil by the temperature etc. specified in the Operation
and Maintenance Manual is not observed.
Clogged, broken pipe in oil pan

q Deterioration of oil due to overheating
Clogged strainer in oil pan
Defective regulator valve

Worn journal of bearing
Lack of oil in oil pan
Defective oil pump

Coolant, fuel in oil
Clogged oil filter

Questions
Oil pressure monitor indicates low oil pressure Q w

Non-specified oil is being used Q Q
Replacement of filters has not been carried out according to Operation and Maintenance
w
Manual
Indicates pressure drop at low idle w
Indicates pressure drop at low, high idle Q w w w Q
Oil pressure monitor
Indicates pressure drop on slopes w
Sometimes indicates pressure drop w Q
Oil level monitor indicates oil level drop w w
Oil level in oil pan is low w
External hydraulic piping is leaking, crushed w
Check items
Oil is milky or smells of diesel oil w

Metal particles are found when oil pan is drained w
Metal particles are found when oil filter is drained w Q
Metal particles are found in oil filter q

Troubleshooting
Inspect oil pan strainer, pipe directly q q

See S-13
Oil pump rotation is heavy, there is play in oil pump q

Valve and spring of regulator valve are fatigued, damaged q
Inspect oil filter directly q
If oil level sensor is replaced, oil level monitor indicates normally q
Replace
Replace
Replace
Replace
Correct
Adjust
Clean
Clean
Add
Remedy
40-600 20 WA320, 320PZ-6

S-13 Oil level rises (Entry of coolant or fuel) SEN04199-01
S-13 Oil level rises (Entry of coolant or fuel) 1
General causes why oil level rises Causes

q Coolant in oil (milky)
Defective seal of auxiliary equipment (pump, compressor)

q Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for S-11 Oil is in coolant
Broken oil cooler core, O-ring

Worn, damaged rear oil seal
Defects in supply pump

Broken injector, O-ring
Questions

Fuel must be added more frequently w w
Coolant must be added more frequently Q Q
There is oil in coolant Q Q Q Q w
Oil smells of diesel fuel w w
Oil is milky Q Q
When engine is started, drops of water come from muffler Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears,
w Q
Check items
or coolant spurts back

Exhaust smoke is white Q
Oil level in damper chamber is low w
Oil level in hydraulic tank of machine is low w

Remove injector and inspect O-ring. q
Troubleshooting
Inspect cylinder block directly q q

Inspect rear oil seal directly q
Pressure-tightness test of oil cooler shows there is leakage q
Remove and inspect supply pump directly q
Inspect seal of auxiliary equipment directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Remedy
WA320, 320PZ-6 40-600 21

SEN04199-01 S-14 Coolant temperature becomes too high (overheating)
S-14 Coolant temperature becomes too high (overheating) 1
General causes why coolant temperature becomes too Causes

high
Defective radiator cap (pressure valve)
Defective coolant temperature gauge

q Lack of cooling air (deformation, damage of fan)
Rise in power train oil temperature

Defective operation of thermostat
Slipping fan belt, worn fan pulley

q Drop in heat dissipation efficiency
Clogged, crushed radiator fins

q Problem in coolant circulation system
Clogged, broken oil cooler
Broken fan pulley bearing

q Rise in oil temperature in power train

o Carry out troubleshooting on applicable machine
Clogged radiator core

Lack of coolant
Questions
Sudden overheated Q w Q
Condition overheating
Always tends to overheat Q Q w w Q
Rises quickly Q Q w
Coolant temperature gauge
Does not go down from red range w
Radiator coolant level monitor indicates drop of coolant level Q w
Engine oil level has risen, oil is milky w w Q
Fan belt tension is low w
When fan pulley is turned, it has play w
Milky oil is floating on coolant Q Q w
There are excessive air bubbles in radiator, coolant spurts back w
w
Check items
When light bulb is held behind radiator core, no light passes through
Radiator shroud, inside of underguard are clogged with dirt or mud w w
Coolant is leaking because of cracks in hose or loose clamps w
Coolant flows out from radiator overflow hose w
Fan belt whines under sudden acceleration w
Power train oil temperature enters red range faster than engine coolant w
temperature

Inspect cylinder block directly q q
Inspect oil cooler directly q
q
Troubleshooting
Temperature difference between upper and lower tanks of radiator is large

Check directly
When operation of thermostat is carried out, it does not open at cracking

q
temperature
Temperature difference between upper and lower tanks of radiator is slight q
Inspect radiator core directly q
When operation of radiator cap is carried out, its cracking pressure is low q
Inspect fan belt, pulley directly q
When coolant temperature is measured, it is found to be normal q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Add
Remedy
40-600 22 WA320, 320PZ-6

S-15 Abnormal noise is made SEN04199-01
S-15 Abnormal noise is made 1
General causes why abnormal noise is made Causes

q Abnormality due to defective parts
Deformed cooling fan, loose fan belt, interference of fan belt

Defective inside of muffler (dividing board out of position)
q Abnormal combustion
Leakage of air between turbocharger and cylinder head

q Air sucked in from intake system
Improper fuel injection timing (abnormality in coolant

a Judge if the noise is an internal noise or an external
Broken dynamic valve system (valve, rocker lever)

Interference of turbocharger, seized turbocharger
temperature sensor, boost temperature sensor)

noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently. Accordingly, the
Excessive wear of piston ring, cylinder

engine sound becomes a little larger. This does not indi-
cate abnormality, however.
a When the engine is accelerated, it is operated in the
Improper gear train backlash

acceleration mode and its sound becomes a little larger
Removed, seized bushing

Clogged, seized injector

for up to about 3 seconds. This does not indicate abnor-
Dirt caught in injector

mality, however.

Degree of use of machine Operated for long period E
Questions
Gradually occurred Q Q
Condition of abnormal noise
Suddenly occurred Q Q Q
Non-specified fuel is being used Q
Metal particles are found when oil filter is drained w w
Air leaks between turbocharger and cylinder head w
When engine is cranked, abnormal sound is generated around cylinder head w w
When engine is cranked, beat noise is generated around muffler w
Check items

some cylinders is low w Q

Black Q w Q
Engine does not pick up smoothly and combustion is irregular w
Abnormal noise is loud when engine is accelerated Q Q Q Q
When turbocharger is rotated by hand, it is found to be heavy q

When muffler is removed, abnormal noise disappears q
q
Troubleshooting
Inspect valve clearance directly

Inspect gear train directly q q
Inspect fan and fan belt directly q
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
q q
not change
Abnormal noise is heard only when engine is started q
Confirm with monitoring function q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Remedy
WA320, 320PZ-6 40-600 23

SEN04199-01 S-16 Vibration is excessive
S-16 Vibration is excessive 1
General causes why vibration is excessive Causes

q Defective parts (abnormal wear, breakage)
Misalignment between engine and devices on applicable machine side

q Misalignment between engine and chassis
Improper fuel injection timing (abnormality in coolant temperature
Broken output shaft, parts in damper on applicable machine side

q Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out trou-
bleshooting for S-15 Abnormal noise is made, too.
Stuck dynamic valve system (valve, rocker lever)
Loose engine mounting bolts, broken cushions

Worn main bearing, connecting rod bearing
sensor, boost temperature sensor)

Improper gear train backlash
Worn camshaft bushing
E E E
Questions

Suddenly increased Q Q
Condition of vibration
Gradually increased Q Q Q
Non-specified oil is being used Q Q
Metal particles are found when oil filter is drained w w
Metal particles are found when oil pan is drained w w
Oil pressure is low at low idle Q Q
Check items
Vibration occurs at mid-range speed Q Q

Vibration follows engine speed Q Q Q Q
Exhaust smoke is black w Q

Inspect main bearing and connecting rod bearing directly q
Troubleshooting
Inspect gear train directly q

Inspect camshaft bushing directly q
Confirm with monitoring function q
Inspect engine mounting bolts and cushions directly q
When alignment is checked, radial runout or facial runout is detected q
Inspect output shaft or inside of damper directly q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
40-600 24 WA320, 320PZ-6

S-16 Vibration is excessive SEN04199-01
WA320, 320PZ-6 40-600 25

SEN04199-01

2009 KOMATSU
All Rights Reserved
40-600 26
SEN04200-02
WA320-6
WA320PZ-6
WA320-6 70001 and up

50 Disassembly and assembly 50
100 General information on disassembly

and assembly
How to read this manual ................................................................................................................................. 2
Coating materials list....................................................................................................................................... 4
Special tool list ................................................................................................................................................ 7
Sketches of special tools ...............................................................................................................................11
WA320, 320PZ-6 50-100 1

100 General information on disassembly and assembly
SEN04200-02 How to read this manual
How to read this manual (Rev. 2009.01)1
1. Removal and installation of assemblies
Special tools Removal

q Special tools which are necessary for q In Removal section, the work procedures,
r e mo v a l or i n s ta l l at i o n o f pa r ts a r e precautions and know-how to do the work, and
described as A1, X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for removal
q Also the following information is de- are described as [1], [2] etc. and their part
scribed in the special tool list. numbers, part names and quantities are not
1) Necessity described.
t : Special tools that cannot be substi- q Various symbols used in Removal section are
tuted and should always be used explained and listed below.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market a : Guidance or precautions for the work
2) Distinction of new and existing special [*1] : This mark shows that instructions or precau-
tools tions for parts installation work are given in
N: Tools newly developed for this Installation section.
model. They have a new part num- 6 : Amount of oil or coolant to be drained
4:
ber respectively. Weight of part or component
R: Tools made available by redesign-
ing the existing tools which were
Installation
developed for other models. Each
of them has a new part number q Unless otherwise instructed, installation of
assigned by setting forward the parts is to be done in the reverse order to
part number of the existing tool. removal.
Blank : Tools already available for other q Instructions and precautions for parts installa-
models. They can be used without tion is shown with the mark ([*1], [*2]...) which
any modification. corresponds to the mark in Removal section.
3) Circle mark Q in sketch column: q Common tools that are necessary for installa-
q The sketch of the special tool is pre- tion are described as [1], [2] etc. and their
sented in the section of Sketches of part numbers, part names and quantities are
special tools. not described.
q Part No. of special tools starting with q Marks shown in the Installation section stand
79 T- - : for the following.
* *** ****
means that they are not available
from Komatsu Ltd. (i.e. tools to be k : Precautions related to work safety
made locally). a : Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
5 : Amount of oil or coolant to be replenished

q Various special tools are illustrated for the local
manufacture.
50-100 2 WA320, 320PZ-6

How to read this manual SEN04200-02
2. Disassembly and assembly of assemblies
Special tools Disassembly

q Special tools which are necessary for dis- q In Disassembly section, the work procedures,
assembly and assembly of parts are precautions and know-how to do the work, and
described as A1, X1 etc. and their part the amount of oil and coolant to be drained are
numbers, part names and quantities are described.
described in the special tool list. q Common tools that are necessary for disas-
q Also the following information is described sembly are described as [1], [2] etc. and
in the special tool list. their part numbers, part names and quantities
1) Necessity are not described.
t : Special tools that cannot be substi- q The meanings of the symbols used in Disas-
tuted and should always be used. sembly section are as follows.
q : Special tools that will be useful if avail-
able and are substitutable with tools k : Precautions related to work safety
available on the market. a : Guidance or precautions for the work
2) Distinction of new and existing special 6 : Amount of oil or coolant drained
tools
N: Tools newly developed for this
model. They have a new part num- Assembly
ber respectively. q In Assembly section, the work procedures,
R: Tools made available by redesign- precautions and know-how to do the work, and
ing the existing tools which were the amount of oil and coolant to be replenished
developed for other models. Each are described.
of them has a new part number q Common tools that are necessary for assem-
assigned by setting forward the bly are described as [1], [2] etc. and their
part number of the existing tool. part numbers, part names and quantities are
Blank : Tools already available for other not described.
models. They can be used without q The meanings of the symbols used in Assem-
any modification. bly section are as follows.
3) Circle mark Q in sketch column:
k
q The sketch of the special tool is pre- : Precautions related to work safety
sented in the section of Sketches of a : Guidance or precautions for the work
2 : Type of coating material
special tools.
3 : Tightening torque
q Part No. of special tools starting with
5
79 T- - :
* *** ****
means that they are not available
: Amount of oil or coolant to be replenished
from Komatsu Ltd. (i.e. tools to be
made locally).
q Various special tools are illustrated for the local
manufacture.
WA320, 320PZ-6 50-100 3

SEN04200-02 Coating materials list
Coating materials list 1

(Rev. 2009.08)
a The recommended coating materials such as adhesives, liquid gaskets, and greases used for disas-
sembly and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this manual.
Cate- Komatsu
Part No. Capacity Container Main features and applications
gory code
q Use to prevent rubber gaskets, rubber cushions,

LT-1A 790-129-9030 150 g Tube
and cork plugs from coming out.
q Use for plastic (except polyethylene, polypropy-
20 g Polyethylene lene, tetrafluoroethylene and vinyl chloride), rub-
LT-1B 790-129-9050
(2 pcs.) container ber, metal, and non-metal parts which require
immediate and strong adhesion.
Polyethylene q Features: Resistance to heat and chemicals.
LT-2 790-129-9040 50 g
container q Use to fix and seal bolts and plugs.
790-129-9060 Adhesive:
(Set of adhe- 1 kg
LT-3 Can q Use to bond and seal metal, glass and plastics.
sive and hard- Hardener:
ener) 500 g
Adhesive
Polyethylene
LT-4 790-129-9040 250 g q Use to seal plugs for blank holes
container
Holtz
790-129-9120 75 g Tube q Heat-resistant seal used to repair engines.
MH 705
q Instantaneous adhesive.
ThreeBond Polyethylene q Curing time: From 5 sec. to 3 min.
790-129-9140 50 g
1735 container q Use mainly to bond metals, rubbers, plastics, and
woods.
q Instantaneous adhesive.
Aron-alpha Polyethylene q Quick-curing type (max. strength is obtained after
790-129-9130 2g
201 container 30 minutes)
q Use mainly to bond rubbers, plastics, and metals.
q Features: Resistance to heat and chemicals.
Loctite Polyethylene
79A-129-9110 50 cc q Use for fitted portions subjected to high tempera-
648-50 container
ture.
q Use to seal various threaded portions, pipe joints,
Polyethylene and flanges.
LG-5 790-129-9080 1 kg
container q Use to seal taper plugs, elbows, and nipples for
hydraulic piping.
q Features: Silicon-based heat and cold-resistant
sealant.
LG-6 790-129-9160 200 g Tube
q Use to seal flange surfaces and threaded portions.
Liquid gasket
q Use to seal oil pan, final drive case, etc.

q Features: Silicon-based quick-curing sealant.
LG-7 790-129-9170 1 kg Tube q Use to seal flywheel housing, intake manifold, oil
pan, thermostat housing, etc.
LG-8 q Features: Silicon-based, heat and cold-resistant,
ThreeBond 419-15-18131 100 g Tube vibration-resistant, impact-resistant sealant.
1207B q Use to seal transfer case, etc.
q Use for rough surfaces such as the circle gear top
LG-9
seal which is not clamped by bolts, gaps in the
ThreeBond 790-129-9310 200 g Tube
weld which must be caulked, etc.
1206D
q Can be coated with paint.
50-100 4 WA320, 320PZ-6

Coating materials list SEN04200-02
Cate- Komatsu
gory code
LG-10 q Use as lubricant/sealant when installing the radia-
ThreeBond 790-129-9320 200 g Tube tor hoses to the water tubes.
Liquid gasket
1206E q Can be coated with paint.

LG-11 q Feature: Can be used together with solid gaskets.
ThreeBond 790-129-9330 200 g Tube q Use for covers of the transmission case and steer-
1121 ing case etc.
ThreeBond
790-129-9090 100 g Tube q Liquid gasket used to repair engine.
1211
q Use to prevent galling and seizure of press-fitted
Molybdenum disulfide
portions, shrinkage-fitted portions, and threaded

LM-P 09940-00040 200 g Tube
portions.
lubricant
q Use to lubricate linkages, bearings, etc.

q Spray type
q Thin molybdenum disulphide films are made on
09995-00250 190 g Can metal surfaces to prevent the metals from galling.
q Use for the drive shaft splines, needle bearings,
various link pins, bolts, etc.
prevention compound
q Feature: Seizure and galling prevention com-

Seizure
LC-G pound with metallic super-fine-grain, etc.

NEVER- Can q Use for the mounting bolt in the high temperature
SEEZ area of the exhaust manifold and the turbocharger,
etc.
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI (*) q Feature: Lithium grease with extreme pressure lu-
SYGA-160CNLI Various Various
*: For cold brication performance, general purpose type.
SYG0-400LI-A
district
(*)
SYG0-160CNLI
(*)
q Use for parts under heavy load.
Molybde- Caution:
num disul- SYG2-400M 400 g 10 Bellows-type q Do not use this grease for rolling bearings like
fide grease SYG2-400M-A 400 g 20 container swing circle bearings, etc. and spline.
LM-G SYGA-16CNM 16 kg Can q Use this grease for work equipment pins only
(G2-M) when installing them, but do not use it after-
ward.
SYG2-400T-A
Grease
Hyper White
SYG0-400T-A q Seizure resistance, heat resistance and water re-
G2-T, Bellows-type
(*) 400 g sistance higher than molybdenum disulfide
G0-T (*) container
SYG2-16CNT grease.
*: For cold 16 kg Can
SYG0-16CNT q Not conspicuous on machine since color is white.
district
(*)
Biogrease
G2-B SYG2-400B
G2-BT (*) SYG2-400BT
Bellows-type q Since this grease is biodegradable in short period,
*: For use at (*) 400 g
container it has less impact on microorganisms, animals,
high temper- SYGA-16CNB
16 kg Can and plants.
ature and SYGA-16CNBT
under high (*)
load
q Feature: Silicone grease with wide usable temper-
G2-S ature range, high resistance to thermal-oxidative
ThreeBond 200 g Tube degradation and performance to prevent deterio-
1855 ration of rubber and plastic parts.
q Use for oil seals of the transmission, etc.
WA320, 320PZ-6 50-100 5

SEN04200-02 Coating materials list
Cate- Komatsu
gory code
q Feature: Urea (organic system) grease with heat
Grease
resistance and long life, can be packed into the

G2-U-S
427-12-11871 2 kg Can confined space and left intact until next overhaul.
ENS grease
q Use for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
20 ml
PRIMER tainer (Effective period: four months after date of
580 SUPER manufacture)
417-926-3910
SUNSTAR
q Use as primer for glass.
GLASS Glass con-
20 ml (Effective period: four months after date of
For adhered window glass

PRIMER tainer
manufacture)
580 SUPER
SUNSTAR q Use as primer for painted cab sheet metal
PAINT Glass con- surface.
Primer
22M-54-27230 20 ml
435-95 manufacture)
q Use as primer for black ceramic-coated
SUNSTAR
glass surface and for hard polycarbonate-
GLASS
22M-54-27240 150 ml Can coated surface.
PRIMER
(Effective period: four months after date of
435-41
manufacture)
SUNSTAR q Use as primer for sash (anodized aluminum
SASH Glass con- surface).
22M-54-27250 20 ml
GP-402 manufacture)
SUNSTAR q Use "S" in high-temperature season and "W"
PENGUINE in low-temperature season as adhesive for
Polyethylene
SEAL580 417-926-3910 320 ml glass.
container
SUPER "S" (Effective period: four months after date of
Adhesive
or "W" manufacture)
Sika Japan, q Use as adhesive for glass.
Polyethylene
Sikaflex 20Y-54-39850 310 ml (Effective period: six months after date of
container
For adhered window glass
256HV manufacture)
SUNSTAR q Use as adhesive for glass.
Ecocart (Spe-
PENGUINE 22M-54-27210 320 ml (Effective period: six months after date of
cial container)
SUPER 560 manufacture)
SUNSTAR
q Use to seal glass-to-glass joints.
PENGUINE Polyethylene
417-926-3920 320 ml (Effective period: four months after date of
SEAL No. container
manufacture)
Caulking material
2505
SEKISUI q Use to seal front window.
Polyethylene
SILICONE 20Y-54-55130 333 ml (Effective period: six months after date of
container
SEALANT manufacture)
GE
q Use to seal glass-to-glass joint. Translucent
TOSHIBA
white seal.
SILICONES 22M-54-27220 333 ml Cartridge
(Effective period: 12 months after date of
TOSSEAL
manufacture)
381
50-100 6 WA320, 320PZ-6

Special tool list SEN04200-02
Special tool list 1
a Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
a Necessity: t ............ Special tools that cannot be substituted and should always be used
q ............ Special tools that will be useful if available and are substitutable with tools
available on the market
a New/Redesign: N ............ Tools newly developed for this model. They have a new part number respec-
tively.
R ............ Tools made available by redesigning the existing tools which were developed
for other models. Each of them has a new part number assigned by setting for-
ward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any mod-
ification.
a Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
Sketches of special tools).
New/Remodel
Necessity
Sketch
Q'ty
Component Symbol Part No. Part name Nature of work, remarks
Installation of engine front oil

Engine front oil seal 1 795-799-6400 Seal puller t 1
seal
Installation of engine rear oil
Engine rear oil seal 2 795-799-6500 Seal puller t 1
seal
3 795-799-6700 Puller t 1 Removal of fuel injector
Cylinder head assembly,
4 795-799-1131 Gear t 1 Positioning of crankshaft
fuel injector assembly
5 795-799-8150 Remover q 1 Removal of inlet connector
A
Cylinder head assembly, 6 790-331-1120 Wrench (Angle) q 1 Angle tightening of bolt
engine front oil seal Judgment of cylinder head bolt
assembly 7 795-790-4510 Gauge q 1
length
Removal of cooling fan assem-
Cooling fan assembly 8 791-415-2002 Remover q 1
bly
Fuel supply pump Holding of fuel supply pump
9 795-799-6130 Support t 1
assembly gear
1 790-201-2840 Spacer t 1 Press fitting of output shaft
2 793T-417-1110 Push tool t 1 Q bearing
790-101-5201 Push tool kit t 1
790-101-5311 Plate 1 Press fitting of oil seal of parking
3
790-101-5221 Grip 1 brake case
01010-51225 Bolt 1
793T-417-1120 Push tool t 1 Q
Press fitting of dust seal of park-
4 790-101-5221 Grip t 1
ing brake case
01010-81225 Bolt t 1
5 799-301-1500 Oil leak tester t 1 Operation test of transfer clutch
Transfer assembly and
D
parking brake assembly 6 799-401-3200 Adapter t 1
7 02789-00315 Cap t 1 Removal and installation of
8 799-101-5160 Nipple t 1 parking brake cylinder rod pin
9 790-190-1500 Pump assembly t 1
Removal and installation of
10 790-201-3260 Bolt (12 x 1.75 mm) q 2 parking brake assembly, cage
assembly and front case
11 792-735-2420 Collar t 1 Removal of HST motor 1 shaft
12 792-104-1130 Collar t 1 Disassembly of output shaft and
13 790-101-3101 Bearing puller q 1 gear assembly
14 790-101-2501 Puller q 1 Removal of carrier assembly
WA320, 320PZ-6 50-100 7

SEN04200-02 Special tool list
New/Remodel
Necessity
Sketch
Q'ty
15 790-102-2900 Puller q 1 Disassembly of HST motor 2

16 790-201-1320 Spacer t 1 gear and bearing assembly
Removal of HST motor 1 gear
17 790-101-3501 Gear puller q 1
and outer race
Disassembly of HST motor 1
18 790-101-3401 Bearing puller q 1
gear and outer race
Removal of HST motor 1 gear
19 79G-17L-1000 Bar t 1
shaft and bearing
20 795-100-1291 Sleeve driver t 1 Removal of clutch housing
Disassembly of HST motor 1, 2
Transfer assembly and 21 796-430-1110 Push tool t 1
D gear and bearing assembly
parking brake assembly
Assembly of HST motor 1 gear
22 790-470-1410 Collar t 1
and outer race
Installation of HST motor 1 gear
23 796-667-1310 Collar t 1
shaft and bearing
24 79G-05V-1400 Bar t 2 Installation of front case
25 791-126-0211 Adapter t 1 Press fitting of cage and bearing
Commercially Measurement of output shaft
26 Torque wrench q 1
available and rotation torque
Measurement of parking brake
27 790-434-1470 Push tool q 1
and plate
Press fitting of axle shaft bear-
793T-623-1170 Push tool t 1 Q
1 ing inner race
793T-422-1440 Push tool t 1 Q
793T-422-1410 Seal support t 1 Q
2 793T-422-1420 Seal support t 1 Q Axle shaft oil seal support
01016-50860 Bolt t 6
793T-659-1110 Push tool t 1 Q Press fitting of axle shaft bear-
3
790-201-2750 Spacer t 1 ing inner race
Adjustment of axle shaft bearing
4 793T-422-1430 Holder t 1 Q
shim
790-101-5271 Plate 1
5 Removal of axle shaft
790-101-5221 Grip 1
Axle housing assembly H
01010-51225 Bolt 1
6 790-101-3101 Bearing puller q 1 Removal of axle shaft bearing
7 790-101-3501 Gear puller q 1
791T-465-1130 Push tool t 1 Q Removal of ring gear
8
790-201-2670 Plate t 1
Installation of planetary carrier
9 799-501-1120 Pin t 1
roll pin
10 790-445-5980 Guide bar t 1
pinion gear shaft
Commercially Measurement of planetary
11 Dial gauge q 1
available carrier end play
79A-264-0021
Measurement of housing
12 or commer- Push-pull scale q 1
starting torque
cially available
50-100 8 WA320, 320PZ-6

Special tool list SEN04200-02
New/Remodel
Necessity
Sketch
Q'ty
13 799-301-1500 Oil leak tester t 1 Operation check of clutch piston

14 797-101-1211 Wrench t 1
pinion shaft nut
No-load operation torque of
15 793-615-1100 Wrench t 1
limited slip differential
16 790-201-2840 Push tool t 1 Press fitting of pinion shaft
17 797T-423-1320 Push tool t 1 Q bearing
Press fitting of pinion shaft cage
18 792T-413-1130 Push tool t 1 Q
oil seal
Installation of brake piston and
19 793-520-2202 Installer q 3
check for brake oil leak
20 790-190-1500 Pump assembly t 1
21 799-101-5210 Nipple t 1 Check for brake oil leak
22 793T-422-1611 Plate t 1 Q
23 791T-465-1210 Push tool t 1 Q Removal of shaft
24 790-201-3280 Bolt (14 x 2.0 mm) q 4 Removal of cage assembly
Differential assembly H Removal and installation of
25 790-201-3260 Bolt (12 x 1.75 mm) q 2
upper cover and bearing carrier
Removal of pinion gear assem-
26 791-615-2130 Sleeve t 1
bly
27 790-101-2501 Puller t 1 Removal of carrier bearing
Removal of differential case
28 79G-05V-1400 Bar t 1
bearing outer race
Commercially
29 Depth gauge q 1 Selection of plate thickness
available
Commercially Measurement of no-load opera-
30 Torque wrench q 1
available tion torque of sun gear shaft
31 791T-630-2230 Push tool t 1 Q Installation of carrier bearing
Commercially Measurement of backlash of
32 Dial gauge q 1
available bevel gear
Installation of long cage shaft
33 790-201-2830 Spacer t 1
bearing
Installation of long cage shaft
34 791-126-0211 Adapter t 1
assembly
790-502-1003 Repair stand t 1 Disassembly and assembly of
1
790-101-1102 Hydraulic pump t 1 hydraulic cylinder
790-102-2303
Wrench assembly Removal and installation of
2 or t 1
(for steering) cylinder head
790-102-3802
3 790-302-1340 Socket (for steering) t 1
Hydraulic cylinder piston nut
U
assembly 790-201-1702 Push tool kit t 1
790-101-5021 Grip 1
01010-50816 Bolt 1 Press fitting of cylinder head
4
790-201-1821 Push tool (Lift) 1 bushing
790-201-1831 Push tool (Bucket) 1
790-201-1741 Push tool (Steering) 1
WA320, 320PZ-6 50-100 9

SEN04200-02 Special tool list
New/Remodel
Necessity
Sketch
Q'ty

790-101-5021 Grip 1
01010-50816 Bolt 1
5 Installation of dust seal
790-201-1630 Plate (Lift) 1
790-201-1640 Plate (Bucket) 1
790-201-1550 Plate (Steering) 1
Hydraulic cylinder 6 790-720-1000 Expander q 1
U
assembly
796-720-1680 Ring (Lift, Bucket) q 1
07281-01589 Clamp (Lift, Bucket) q 1
7
796-720-1740 Ring (Steering) q 1
Installation of piston ring
07281-00809 Clamp (Steering) q 1
Wrench assembly
790-102-4300 t 1
8 (Lift, Bucket)
790-102-4310 Pin t 2
1 793-498-1120 Clear plate t 2
Adjustment of clearance of
1 2 793-498-1130 Plate t 2
Operator's cab glass window glass
(stuck glass)
X 3 793-498-1110 Magnet t 2
2 793-498-1210 Lifter (Suction cup) t 2
window glass
790-101-5281 Plate 1 Removal of bearing of front
1
790-101-5221 Grip 1 frame lower hinge
01010-51225 Bolt 1
Center hinge pin Y Removal of bearing of front
2 793-840-1410 Push tool t 1
frame upper hinge
Press fitting of bearing of front
3 793-840-1420 Push tool t 1
frame upper hinge
Press fitting of bearing of front
4 793-415-1180 Push tool t 1
frame lower hinge
50-100 10 WA320, 320PZ-6

Sketches of special tools SEN04200-02
Sketches of special tools 1
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D2 Push tool
9JF00891
D4 Push tool
9JF00892
WA320, 320PZ-6 50-100 11

SEN04200-02 Sketches of special tools
H1-1 Push tool a Use this tool with tool H1-2 jointed to it.
H1-2 Push tool a Use this tool with tool H1-1 jointed to it.
50-100 12 WA320, 320PZ-6

H2 Seal support
H2 Seal support
WA320, 320PZ-6 50-100 13

H3 Push tool
9JF00899
H4 Holder
50-100 14 WA320, 320PZ-6

H8 Push tool
COW16159
H17 Push tool
WA320, 320PZ-6 50-100 15

H18 Push tool
9JF00901
H22 Plate
50-100 16 WA320, 320PZ-6

H23 Push tool
H31 Push tool
WA320, 320PZ-6 50-100 17

SEN04200-02

2010 KOMATSU
All Rights Reserved
50-100 18
SEN04201-03
WA320-6
WA320PZ-6
WA320-6 70001 and up


Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 5
Removal and installation of cylinder head assembly .................................................................................... 13
Removal and installation of engine hood assembly ...................................................................................... 25
Removal and installation of radiator.............................................................................................................. 28
Removal and installation of air aftercooler .................................................................................................... 31
Removal and installation of hydraulic oil cooler assembly ............................................................................ 33
Removal and installation of engine assembly ............................................................................................... 35
Removal and installation of engine front oil seal assembly .......................................................................... 41
Removal and installation of engine rear oil seal assembly ........................................................................... 44
Removal and installation of cooling fan and fan motor assembly ................................................................. 47
Removal and installation of fuel tank assembly ............................................................................................ 50
WA320, 320PZ-6 50-200 1

SEN04201-03 Removal and installation of fuel supply pump assembly
Removal and installation of fuel 3. Disconnect wiring harness connector CN-CP3

supply pump assembly 1
(3) from fuel supply pump (4).
Special tools 4. Disconnect fuel filter hoses (5) and (6) from
fuel supply pump (4).
New/Remodel
Necessity
Sketch
5. Disconnect fuel return hose (7) from fuel sup-
Q'ty
ply pump (4).
a If mud is sticking, lock (L) may become
stiff. Accordingly, clean the connecting
A 9 795-799-6130 Support t 1
area.
a Press lock (L) from both sides and pull out
Removal hose (5).
k Stop the machine on a level ground and set a Plug the disconnected hose to prevent
the lock bar to the frame to fix the front and fuel leakage.
rear frames.
k Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k Disconnect the cable from the negative ()
terminal of the battery.
1. Open and fix right engine side cover (1).

a Check that the cover is locked securely.
6. Disconnect fuel supply hose (8) from fuel sup-

ply pump (4). [*1]
7. Remove boot (9).
8. Remove 2 clamps of fuel high-pressure pipe

(10) between the supply pump and common
rail.
2. Remove fuel prefilter and bracket assembly 9. Disconnect fuel high-pressure pipe (10) from
(2). fuel supply pump (4). [*2]
a Fix fuel prefilter and bracket assembly (2) a Remove the boot on the common rail side
to the machine with ropes. of high-pressure pipe (10) and loosen the
sleeve nut.
50-200 2 WA320, 320PZ-6

Removal and installation of fuel supply pump assembly SEN04201-03
10. Remove 3 mounting nuts at part (A) and fuel

supply pump assembly (11). [*3]
4) Set puller [3] to puller [2].

5) Tighten center bolt [4] to disconnect gear
a Remove fuel supply pump assembly (11) (18) from shaft (21).
and the gear together. The gear does not 6) Remove nut (19), lock washer (20), and
have a positioning mark (missing tooth), gear (18) from shaft (21).
etc.
11. When removing the gear from the fuel supply

pump, follow the procedure below. [*4]
1) Using tool A9 and wrench handle (width
across flats of square: 1/2 inch) [1], fix
gear (18).
2) Loosen nut (19).
a Do not remove nut (19) from the
shaft.
3) Set puller [2] between the flange and gear
(18).
WA320, 320PZ-6 50-200 3

SEN04201-03 Removal and installation of fuel supply pump assembly
Installation [*4]
q Carry out installation in the reverse order to q Installation procedure for gear (18)
removal. a Before installing gear (18), securely clean and
a The internal parts of the fuel hose adapter dry the mating faces of shaft (21) and gear
may be damaged when it is removed. (18).
Accordingly, do not reuse the fuel hose but 1. Install gear (18) to shaft (21).
use new one when assembling again as a
rule. 2. Install lock washer (20) and nut (19) and lightly
tighten nut (19) with the hand.
[*1]
3 Joint bolt: 19.6 29.4 Nm {2.0 3.0 kgm} 3. Using tool A9 and wrench handle (width across
flats of square: 1/2 inch) [1], fix gear (18).
[*2]
q How to install high-pressure pipe (10) 4. Tighten nut (19).
1. Tighten the sleeve nut with the fingers. 3 Nut (19): 105 5 Nm {10.7 0.51 kgm}
2. Check that the high-pressure pipe is installed

correctly and tighten the sleeve nut to the fol-
lowing torque.
3 Sleeve nut:
35 3.5 Nm {3.57 0.36 kgm}
k Be sure to use the genuine fuel high-
pr e s s u r e p i pe c l a m p a nd s t r i c t l y
ob s e r v e t h e s p e c i f i e d t i g ht e n i ng
torque.
3. Install boot (9).

a Direct the slit of the boot down.
a The boot is installed so that fuel will not
spout over the hot parts of the engine and
catch fire when it leaks for some reason.
[*3]
a If too much grease is applied to O-ring (13), it
will ooze out. Accordingly, do not apply grease
so much. (Apply grease to the O-ring groove
area of part (B).)
a When installing new fuel supply pump mount-
ing stud bolts (14) to replace the existing ones,
apply LOCTITE (LT-2) to them.
Install fuel supply pump (12).

3 Fuel supply pump mounting nut:
24 4 Nm {2.45 0.41 kgm}
q Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, Bleeding air from fuel
circuit.
50-200 4 WA320, 320PZ-6

Removal and installation of fuel injector assembly SEN04201-03
Removal and installation of fuel 4. Remove 4 muffler mounting bolts on the left (2)
injector assembly 1
and 4 (3) on the right.
Special tools 5. Lift off muffler (4).

a Take care that the muffler will not interfere
New/Remodel
with water drain tube (5).
Necessity
4
Sketch
Q'ty
Symbol Part No. Part name Muffler assembly: 40 kg
6. Remove muffler mounting bracket (6) from the

3 795-799-6700 Puller t 1 right.
A 4 795-799-1131 Gear t 1
5 795-799-8150 Remover q 1
Removal
k Stop the machine on a level ground and set
the lock bar to the frame to fix the front and
rear frames.
k If the radiator coolant temperature is high,
you may scald yourself with the hot cool- 7. Disconnect engine intake air heater wiring har-
ant. Wait until the coolant is cooled, and ness terminal CN-E07B (7). [*1]
then drain the coolant.
1. Drain the coolant from the radiator.

6 Radiator: Approx. 26 l
2. Remove the engine hood assembly. For

details, see Removal and installation of
engine hood assembly.
3. Remove muffler cover (1).
WA320, 320PZ-6 50-200 5

SEN04201-03 Removal and installation of fuel injector assembly
8. Remove clamps (8) and (9). [*2]
9. Remove air hose (10) and air inlet elbow (11)

together.
10. Remove mounting bolt (12a) and then remove

the engine intake air heater (12) (electrical
intake air heater). [*3]
11. Remove 2 wiring harness clamps (13).
12. Disconnect wiring harness connector (14).

a While pressing the lock of wiring harness
connector (14), pull the connector in the
direction of the arrow.
14. Using hexagonal wrench (width across flats:
13. Disconnect 3 wiring harness connectors (15). 3 mm), remove blow-by duct (17). [*5]
[*4]
a While pressing the lock of the wiring har- 15. Remove 6 mounting nuts (18) and cylinder
ness connector with flat-head screwdriver head cover (19). [*6]
[1], pull the connector in the direction of
the arrow.
a Move wiring harness (16) toward the
intake manifold.
50-200 6 WA320, 320PZ-6

16. Remove 6 boots (20). [*7]
17. Remove 6 high-pressure pipes (21). [*8]
19. Remove the 12 mounting bolts and rocker

arms (23).
a Loosen locknuts (24), and then loosen
18. Position the crankshaft according to the follow- adjustment screws (25) by 2 3 turns so
ing procedure. that an excessive force will not be applied
1) Remove plug (22) under the starting motor to the push rod when the rocker arm is
and set tool A4. installed.
2) Rotate the crankshaft forward (counter-
clockwise seeing from the flywheel side)
to set marks (M1) and (M2).
Mark (M1):Top of projection of front cover
Mark (M2):A wide slit on slitted revolution
sensor disc at rear of crank-
shaft pulley
Mark (M3):Yellow paint on vibration
damper (on prolongation of
wide slit (M2))
a Set the projection top of mark (M1)
within the wide slit (M2).
a When the marks are set as above,
the piston of the No. 1 or No. 6 cylin-
der is 76 88 before the top dead 20. Remove 12 crossheads (26).
center. a Record the installed positions and the
a See Testing and adjusting, Adjusting shapes of holes (a) and (b) of the cross-
valve clearance. heads. (When assembling, install each
a Use tool A4 to rotate the crankshaft. crosshead to the intake/exhaust valve
from which it was removed.)
WA320, 320PZ-6 50-200 7

22. Remove 2 wiring harness mounting nuts (30)

from fuel injector assembly (29).
Wiring harness color Cylinder No.
White 1, 3, 5
Black 2, 4, 6
Do not remove the connector (42) of injector

harness from rocker housing unless it is neces-
sary.
23. Remove 2 mounting bolts (31) of fuel injector

assembly (29).
21. Remove retaining nuts (27) and 6 inlet connec-

tors (28).
a Before removing, clean the inlet connec-
tors carefully so that mud, etc. sticking
around them will not enter their holes.
a Tool A5 is set for removal of inlet connec-
tor (28). (See the special tools list.)
24. Using tool A3, remove fuel injector assembly

(29).
a Take care that dirt and foreign matter will
not enter the fuel injector assembly
mounting area.
50-200 8 WA320, 320PZ-6

Installation 6) Apply engine oil (EO30) to O-ring (35) of

a The internal parts of the fuel hose adapter may inlet connector (28) and the mounting hole
be damaged when it is removed. Accordingly, on the cylinder head side.
do not reuse the fuel hose but use new one 7) Insert inlet connector (28) securely, while
when assembling as a rule. setting part (B) to the groove on the cylin-
When replacing the fuel injector assembly with der head side.
new one, be sure to replace the inlet connector
with new one, too.
1. Fuel injector assembly

a Check that the fuel injector sleeve is free
from flaw and dirt.
1) Fit O-ring (32) and gasket (33) to fuel
injector (29).
2) Apply engine oil (EO30) to O-ring (32) of
fuel injector (29) and the mounting hole on
the cylinder head side.
3) While setting convex and concave parts
(A), install holder (34) to fuel injector (29).
8) Secure inlet connector (28) by tightening

retaining nut (27) lightly.
3 Retaining nut (27):
15 5 Nm {1.5 0.5 kgm}
9) Tighten 2 mounting bolts (31) of fuel injec-
tor (29) alternately.
3 Fuel injector mounting bolt (31):
8.0 0.8 Nm {0.8 0.08 kgm}
10) Tighten retaining nut (27).
3 Retaining nut (27):
50 5 Nm {5.1 0.5 kgm}
4) Insert fuel injector (29) in the cylinder

head, directing its fuel inlet hole toward
the air intake manifold.
tor (29) by 3 4 turns.
WA320, 320PZ-6 50-200 9

11) Install the wiring harnesses to fuel injector

(29) and tighten 2 mounting nuts (30).
3 Wiring harness mounting nut (30):
1.5 0.25 Nm {0.15 0.03 kgm}
a Installed positions of wiring har-
nesses
Wiring harness
Cylinder No.
color
White 1, 3, 5
Black 2, 4, 6
q Precautions for installing inlet connector

1) When replacing the fuel injector assembly
with new one, be sure to replace inlet con-
nector, too.
2) Check the inlet connector visually. If it has
any of the following faults, replace it.
1] There is a burr or a worn part at front
end (a) or rear end (b) of the inlet
connector.
2] There is foreign matter in the edge fil-
ter at rear end (c) of the inlet connec-
a When the connector of injector harness is tor.
removed. 3] The O-ring at upper part (d) of the
When assembling the injector harness inlet connector is cracked or deterio-
connector (42) to the housing, apply gas- rated.
ket sealant (LG-7) to the O-ring portion
(43) and the flange face of connector (44).
When applying gasket sealant (LG-7) to
the O-ring portion, be sure to apply a
string of LG-7 f 3 mm in diameter until O-
ring groove is completely filled.
If the O-ring is damaged, replace as a har-
ness assembly.
3 Connector flange mounting bolt (45):
10 2 Nm {1 0.2 kgm}
50-200 10 WA320, 320PZ-6

3) Check the inlet connector visually. If it has 2. Crosshead and rocker arm assembly
any of the following faults, replace it and 1) Install the crosshead and rocker arm.
fuel injector assembly together. a The shapes of holes (a) and (b) of
q There is a worn part or an uneven each crosshead are different. Accord-
seat contact mark on sealing face (e) ingly, when reusing the crossheads,
at the front end of the inlet connector. install each of them to the same
a If high-pressure fuel leaks intake/exhaust valve in the same
through the inlet connector, the direction as it was installed.
seal face will have fine streaks or 2) Check that the ball of adjustment screw
cracks. (25) is set in the push rod socket securely
and then tighten mounting bolts (36).
3 Rocker arm mounting bolt (36):
36 5 Nm {3.7 0.5 kgm}
3) Adjust the valve clearance. For details,
see Testing and adjusting, Adjusting
valve clearance.
3 Locknut (24):
24 4 Nm {2.4 0.4 kgm}
WA320, 320PZ-6 50-200 11

q Carry out the following installation in the 1) Temporarily install fuel high-pressure
reverse order to removal. pipes (36) (41).
3 Sleeve nut:
[*1] 0.2 0.8 Nm {0.02 0.08 kgm}
3 Wiring harness terminal CN-E07B (7): 2) Tighten fuel high-pressure pipes (36)
4.0 0.6 Nm {0.41 0.06 kgm} (41) in the following order.
1] Tighten the cylinder head side of fuel
[*2] high-pressure pipes (36) and (41).
3 Clamp (8): 7 1 Nm {0.71 0.1 kgm} 2] Tighten the common rail side of fuel
3 Clamp (9): 10.5 0.5 Nm {1.07 0.05 kgm} high-pressure pipes (36) and (41).
3] Tighten the cylinder head side of fuel
[*3] high-pressure pipes (37), (38), (39)
3 Engine intake air heater mounting bolt (12a): and (40).
24 4 Nm {2.4 0.4 kgm} 4] Tighten the common rail side of fuel
high-pressure pipes (37), (38), (39)
[*4] and (40).
k Install each fuel high-pressure pipe and 3 Sleeve nut:
wiring harness at least 10 mm apart from 35 3.5 Nm {3.6 0.4 kgm}
each other. 3) Install 6 boots (20) to the fuel high-pres-
sure pipes.
[*5] a Direct the slit of the boot out and
3 Blow-by duct (17) mounting bolt: down.
7 2 Nm {0.7 0.2 kgm} a The boots are installed so that fuel
will not spout over the hot parts of the
[*6] engine to catch fire when it leaks for
3 Cylinder head cover mounting nut (18): some reason.
24 4 Nm {2.4 0.4 kgm}
[*7], [*8]
k Do not bend the fuel high-pressure pipe to
correct before installing.
k Be sure to use the genuine fuel high-pres-
sure pipe clamps and observe the tighten-
ing torque.
a If the taper seal area of the fuel high-pressure
pipe has any of the following defects, replace
the fuel high-pressure pipe.
q There is visible lengthwise slit (b) or spot (c) in
range (a) of 2 mm from the end.
q Taper seal end (d) at 2 mm from the end has
stepped-type wear which your nail can feel. q Bleeding air
circuit.
q Refilling with coolant

Add coolant through the coolant filler to the
specified level. Run the engine to circulate the
coolant through the system. Then, check the
coolant level again.
5 Total amount of coolant: 26.5 l
(For details, see Table of fuel, coolant
and lubricants)
50-200 12 WA320, 320PZ-6

Removal and installation of cylinder head assembly SEN04201-03
Removal and installation of 4. Remove 4 muffler mounting bolts (2) on the left
cylinder head assembly 1
and 4 (3) on the right.
Special tools 5. Lift off muffler (4).

a Take care that the muffler will not interfere
New/Remodel
with water drain tube (5).
Necessity
4
Sketch
Q'ty
Symbol Part No. Part name Muffler assembly: 40 kg
6. Remove right muffler mounting bracket (6).

3 795-799-6700 Puller t 1
4 795-799-1131 Gear t 1
A 5 795-799-8150 Remover q 1
6 790-331-1120 Wrench (angle) q 1
7 795-790-4510 Gauge q 1
Removal
rear frames.
k Disconnect the cable from the negative () 7. Disconnect engine intake air heater wiring har-
terminal of the battery. ness terminal CN-E07B (7). [*1]
you may scald yourself with the hot cool-
ant. Wait until the coolant is cooled, and


WA320, 320PZ-6 50-200 13

SEN04201-03 Removal and installation of cylinder head assembly
8. Remove clamps (8) and (9). [*2] 3) Disconnect wiring harness connector (16).
4) Remove bracket (17).
9. Remove air hose (10) and intake air inlet elbow 5) Remove air conditioner compressor
(11) together. assembly (18). [*4]
a Fix air conditioner compressor assembly
10. Remove mounting bolt (12a) and engine intake (18) to the machine with ropes.
air heater (12) (electrical intake air heater). [*3]
12. Disconnect fuel filter hoses (19) and (20).

11. Remove the air conditioner compressor a If mud is sticking, lock (L) may become
assembly according to the following proce- stiff. Accordingly, clean the connecting
dure. area.
1) Loosen air conditioner compressor assem- a Press lock (L) from both sides and pull out
bly mounting bolt (13). hose (20).
2) Loosen air conditioner compressor drive a Plug the disconnected hoses to prevent
belt adjustment bolt (14) and remove belt fuel leakage.
(15). [*4]
13. Disconnect fuel return hose (21).
14. Remove fuel prefilter hose clamp (22).
15. Remove 2 air conditioner compressor hose

clamps (23).
16. Remove fuel filter and bracket assembly (24).
50-200 14 WA320, 320PZ-6

17. Remove 2 clamps (25). 21. Remove 2 wiring harness clamps (29).
18. Disconnect engine coolant temperature sensor 22. Disconnect wiring harness connector (30).
connector (26). a While pressing the lock of wiring harness
connector (30), pull the connector in the
19. Disconnect ambient air pressure sensor con- direction of the arrow.
nector (27) according to the following proce-
dure.
1) Slide lock (L1) in the direction of the arrow.
2) Pull out connector (27) in the direction of
the arrow while pressing lock (L2).
20. Disconnect intake air pressure sensor connec-

tor (28).
23. Disconnect 3 wiring harness connectors (31).

[*5]
a While pressing the lock of the wiring har-
ness connector (31) with flat-head screw-
d r iv er [1 ], p ul l t he co nne cto r in th e
direction of the arrow.
a Move wiring harness (32) toward the
intake manifold.
WA320, 320PZ-6 50-200 15

24. Remove the fuel high-pressure pipe according 28. Disconnect heater hose (40).
1) Disconnect fuel drain hose (33). [*6] 29. Disconnect corrosion resistor hose (41).
2) Remove 6 bolts (34). [*7]
3) Disconnect fuel high-pressure pipe (35). 30. Remove corrosion resistor and bracket assem-
[*8] bly (42).
4) Remove 6 high-pressure pipes (36). [*9]
a Loosen the sleeve nut on the common rail
side of each high-pressure pipe.
31. Remove heat insulation plate (43).
25. Disconnect radiator upper hose (37). [*10] 32. Remove bracket (44).
26. Disconnect air aftercooler upper hose and tube 33. Remove cover (45).
assembly (38). [*11]
27. Remove heat insulation cover (39).
34. Remove the alternator assembly according to

1) Disconnect wiring harness terminals CN-
E02 (46) and CN-E03 (47).
50-200 16 WA320, 320PZ-6

2) Remove fan belt (49). 2) Remove mounting bolts (54) of exhaust

q Put the wrench in the concave section manifold (53), leaving some of them
(width across flats: 12.7 mm) of ten- installed. [*13]
sioner assembly (48) and turn it in the
unwinding direction to decrease the
tension of fan belt (49).
k Set the wrench securely to the con-
cave section of tensioner assem-
bly (48) before turning it. (The
spring of tensioner assembly (48)
is stro ng . If th e wrench is set
incompletely and turned, it comes
off and that is very dangerous.)
k After removing belt (49), return ten-
sioner assembly (48) slowly and
carefully.
k Take care not to catch your finger
between the pulley and fan belt 3) Temporarily sling exhaust manifold and
(49) during work. turbocharger assembly (55) and remove
3) Remove alternator assembly (50). the remaining mounting bolts.
4) Lift off exhaust manifold and turbocharger
assembly (55).
4 Exhaust manifold and turbocharger
assembly: 40 kg
35. Remove the turbocharger assembly according

1) Disconnect turbocharger lubricating oil
inlet tube (51) and drain hose (52). [*12]
36. Remove the fuel infector assembly according
1) Using hexagonal wrench (width across
flats: 3 mm), remove blow-by duct (56).
[*14]
2) Remove 6 mounting nuts (57) and cylinder
head cover (58). [*15]
WA320, 320PZ-6 50-200 17

3) Position the crankshaft according to the 4) Remove the 12 mounting bolts and rocker
following procedure. arms (60).
1] Remove plug (59) under the starting a Loosen locknuts (61), and then
motor and set tool A4. loosen adjustment screws (62) by 2
3 turns so that an excessive force will
not be applied to the push rod when
the rocker arm is installed.
2] Rotate the crankshaft forward (coun-

terclockwise seeing from the flywheel
side) to set marks (M1) and (M2).
Mark (M1): Top of projection of front cover 5) Remove 12 crossheads (63).
Mark (M2): A wide slit on slitted revolution a Record the installed positions and the
sensor disc at rear of crank- shapes of holes (a) and (b) of the
shaft pulley crossheads. (When assembling,
Mark (M3): Yellow paint on vibration install each crosshead to the intake/
damper (on prolongation of exhaust valve from which it was
wide slit (M2)) removed.)
a Set the projection top of mark (M1)
within the wide slit (M2).
a There is yellow paint mark (M3) on
the prolongation of wide slit (M2).
a When the marks are set as above,
the piston of the No. 1 or No. 6 cylin-
der is 76 88 before the top dead
center.
a See Testing and adjusting, Adjusting
valve clearance.
a Use tool A4 to rotate the crankshaft.
50-200 18 WA320, 320PZ-6

6) Remove retaining nuts (64) and 6 inlet 9) Using tool A3, remove fuel injector assem-
connectors (65). bly (66).
a Before removing, clean the inlet con- a Take care that dirt and foreign matter
nectors carefully so that mud, etc. will not enter the fuel injector assem-
sticking around them will not enter bly mounting area.
their holes.
a Tool A5 is set for removal of inlet con-
nector (65). (See the special tools
list.)
37. Remove push rods (69).
38. Remove 7 mounting bolts (70) and rocker

housing (71).
7) Remove 2 wiring harness mounting nuts
(67) from fuel injector assembly (66).
Wiring harness color Cylinder No.
White 1, 3, 5
Black 2, 4, 6
8) Remove 2 mounting bolts (68) of fuel

injector assembly (66).
39. Remove 26 mounting bolts (72) and lift off cyl-

inder head assembly (73).
4 Cylinder head assembly: 75 kg
40. Remove cylinder head gasket (74).
WA320, 320PZ-6 50-200 19

Installation 2) Set cylinder head gasket (74).

a The internal parts of the fuel hose adapter may a Check that there is no dirt and foreign
be damaged when it is removed. Accordingly, matter on the cylinder head mounting
do not reuse the fuel hose but use new one surface and in the cylinders.
when assembling as a rule. a Check that the holes of the cylinder
When replacing the fuel injector assembly with head gasket are matched to the holes
new one, be sure to replace the inlet connector of the cylinder head.
with new one, too. 3) Set cylinder head (73) on the cylinder
block.
1. Cylinder head assembly 4) Tighten 26 mounting bolts (72) 2 3 turns
1) Using tool A7, measure stem length (a) of with the fingers, and then tighten them
each cylinder head mounting bolt and according to the following procedure.
check that it is shorter than using limit (b). 2 Threaded part and seat of mounting
(See the special tools list.) bolt: Engine oil (EO30)
q Using limit length of bolt (b): 132.1
mm
a If a bolt is longer than the using limit,
replace it.
q Tightening procedure for mounting bolts

(63).
1] 90 3 Nm {9.2 0.3 kgm}
2] Check the tightening torque of 90 3 Nm
{9.2 0.3 kgm}.
3] 90 5 (Use the angle tightening tool)
a Tighten the mounting bolts in the following
order.
a Tool A6 is set for angle tightening. (See
the special tools list.)
50-200 20 WA320, 320PZ-6

q When not using angle tightening tool

4] After steps 1] and 2], make marks on the
cylinder head and each bolt with a paint.
5] Tighten the bolt by 90 5.
6) Insert fuel injector (66) in the cylinder

head, directing its fuel inlet hole toward
the air intake manifold.
2. Fuel injector assembly tor (66) by 3 4 turns.
a Check that the fuel injector sleeve is free
from flaw and dirt.
1) Fit O-ring (75) and gasket (76) to fuel
injector (66).
fuel injector (66) and the mounting hole on
the cylinder head side.
3) Install holder (77), while setting its con-
cave part to convex part (A) of fuel injector
(66).

inlet connector (65) and the mounting hole
on the cylinder head side.
9) Insert inlet connector (65) securely, while
setting part (B) to the groove on the cylin-
der head side.
4) Install rocker housing (71).

3 Rocker housing mounting bolt (70):
24 4 Nm {2.4 0.4 kgm}
5) Install push rods (69).
WA320, 320PZ-6 50-200 21

10) Secure inlet connector (65) by tightening q Precautions for installing inlet connector
retaining nut (64) lightly. 1) When replacing the fuel injector assembly
3 Retaining nut (64): with new one, be sure to replace inlet con-
15 5 Nm {1.5 0.5 kgm} nector, too.
11) Tighten 2 mounting bolts (68) of fuel injec- 2) Check the inlet connector visually. If it has
tor (66) alternately. any of the following faults, replace it.
3 Fuel injector mounting bolt (68): 1] There is a burr or a worn part at front
8.0 0.8 Nm {0.8 0.08 kgm} end (a) or rear end (b) of the inlet
12) Tighten retaining nut (64). connector.
3 Retaining nut (64): 2] There is foreign matter in the edge fil-
50 5 Nm {5.1 0.5 kgm} ter at rear end (c) of the inlet connec-
13) Install the wiring harnesses to fuel injector tor.
(66) and tighten 2 mounting nuts (67). 3] The O-ring at upper part (d) of the
3 Wiring harness mounting nut (67): inlet connector is cracked or deterio-
1.5 0.25 Nm {0.15 0.03 kgm} rated.
a Installed positions of wiring har-
nesses
Wiring harness
Cylinder No.
color
White 1, 3, 5
Black 2, 4, 6
3) Check the inlet connector visually. If it has

any of the following faults, replace it and
fuel injector assembly together.
q There is a worn part or an uneven
seat contact mark on sealing face (e)
at the front end of the inlet connector.
a If high-pressure fuel leaks
through the inlet connector, the
seal face has fine streaks or
cracks.
50-200 22 WA320, 320PZ-6

3. Crosshead and rocker arm assembly q Carry out the following installation in the
1) Install the crosshead and rocker arm. reverse order to removal.
a The shapes of holes (a) and (b) of
each crosshead are different. Accord- [*1]
ingly, when assembling, install each 3 Wiring harness terminal CN-E07B (7):
crosshead to the intake/exhaust valve 4.0 0.6 Nm {0.41 0.06 kgm}
from which it was removed.
2) Check that the ball of adjustment screw [*2]
(80) is set in the push rod socket securely 3 Clamp (8): 7 1 Nm {0.71 0.1 kgm}
and then tighten mounting bolts (81). 3 Clamp (9): 10.5 0.5 Nm {1.07 0.05 kgm}
3 Rocker arm mounting bolt (81):
36 5 Nm {3.7 0.5 kgm} [*3]
3) Adjust the valve clearance. For details, 3 Engine intake air heater mounting bolt (12a):
see Testing and adjusting, Adjusting 24 4 Nm {2.4 0.4 kgm}
valve clearance.
3 Locknut (79): [*4]
24 4 Nm {2.4 0.4 kgm} Adjust the air conditioner compressor belt tension.
For details, see Testing and adjusting, Adjusting
air conditioner compressor belt tension.
[*5]
k Install each fuel high-pressure pipe and
wiring harness at least 10 mm apart from
each other.
[*6], [*7], [*8], [*9]

k Do not bend the fuel high-pressure pipe to
correct before installing.
k Be sure to use the genuine fuel high-pres-
sure pipe clamps and observe the tighten-
ing torque.
a If the taper seal area of the fuel high-pressure
pipe has any of the following defects, replace
the fuel high-pressure pipe.
q There is visible lengthwise slit (b) or spot (c) in
range (a) of 2 mm from the end.
q Taper seal end (d) at 2 mm from the end has
stepped-type wear which your nail can feel.
WA320, 320PZ-6 50-200 23

1) Temporarily install fuel high-pressure [*12]

pipes (82) (87). 3 Mounting nut of turbocharger lubricating oil
3 Sleeve nut: inlet hose (51): 35 5 Nm {3.5 0.5 kgm}
0.2 0.8 Nm {0.02 0.08 kgm} 3 Mounting bolt of turbocharger lubricating oil
2) Tighten fuel high-pressure pipes (82) drain tube (52): 24 4 Nm {2.4 0.4 kgm}
(87) in the following order.
1] Tighten the cylinder head side of fuel [*13]
high-pressure pipes (82) and (87). q Tighten the exhaust manifold mounting bolts
2] Tighten the common rail side of fuel according to the following procedure.
high-pressure pipes (82) and (87). 3 Exhaust manifold mounting bolts
3] Tighten the cylinder head side of fuel 1st time: Tighten [1] [12] to 24 4 Nm {2.4
high-pressure pipes (83), (84), (85) 0.4 kgm} in order.
and (86). 2nd time:Tighten [1] [12] to 53 6 Nm {5.4
4] Tighten the common rail side of fuel 0.6 kgm} in order.
high-pressure pipes (83), (84), (85) 3rd time: Tighten only [1] [4] to 53 6 Nm
and (86). {5.4 0.6 kgm} in order.
5] Tighten the pump side of high-pres-
sure pipe (35) and then tighten the
common rail side.
3 Sleeve nut:
35 3.5 Nm {3.6 0.4 kgm}
3) Install 6 boots (34) to the fuel high-pres-
sure pipes.
a Direct the slit of the boot out and
down.
a The boots are installed so that fuel
will not spout over the hot parts of the
engine to catch fire when it leaks for
some reason.
4) Install fuel drain hose (33).
3 Joint bolt: [*14]
24 4 Nm {2.4 0.4 kgm} 3 Blow-by duct mounting bolt:
7 2 Nm {0.7 0.2 kgm}
[*15]
3 Cylinder head cover mounting nut (57):
24 4 Nm {2.4 0.4 kgm}
q Bleeding air
system.

[*10] specified level. Run the engine to circulate the
2 Radiator upper hose insertion area: coolant through the system. Then, check the
Gasket sealant coolant level again.
5
(ThreeBond 1206E or equivalent)
Total amount of coolant: 26.5 l
3 Radiator upper hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}
[*11]
3 Air aftercooler upper hose clamp:
10.5 0.5 Nm {1.07 0.05 kgm}
50-200 24 WA320, 320PZ-6

Removal and installation of engine hood assembly SEN04201-03
Removal and installation of 4. Remove partition plate (4).

engine hood assembly 1
Removal
rear frames.
1. Remove exhaust pipe (1).
5. Disconnect radiator overflow hose (5).
2. Open and fix right and left engine side covers

(2).
a Check that the covers are locked securely. 6. Remove 4 bolts (6), then remove cover (7).
3. Open radiator grille (3). 7. Remove 3 air conditioner compressor hose

clamps (8).
8. Remove 4 right and left bolts (9), then remove

partition plate (10).
WA320, 320PZ-6 50-200 25

SEN04201-03 Removal and installation of engine hood assembly
9. Remove stay (11) on the right and left. 12. Remove right and left fenders (15).
13. Remove right and left covers (16).
a Put wooden block [1] under striker (12) to

prevent the radiator assembly from falling
down. 14. Remove hose (17) between the air cleaner and
turbocharger. [*1]
10. Disconnect water separator wiring harness

connector CN-E42 (13). 15. Disconnect 2 washer hoses (18).
11. Remove fuel prefilter and bracket assembly 16. Remove wiring clamp (19).
(14).
a Fix fuel prefilter and bracket assembly 17. Remove rubber cover (20).
(14) to the machine with ropes.
50-200 26 WA320, 320PZ-6

Removal and installation of engine hood assembly SEN04201-03
18. Disconnect rear combination lamp connector 21. Lift off engine hood assembly (24).
4
CN-BR1 (21).
Engine hood assembly: 240 kg
19. Remove 2 front mounting bolts (22) on each of

the right and left sides.
Installation
q Carry out installation in the reverse order to
removal.
[*1]
3 Hose clamp:
10.5 0.5 Nm {1.07 0.05 kgm}
20. Remove 1 rear mounting bolt (23) on each of

the right and left sides.
WA320, 320PZ-6 50-200 27

SEN04201-03 Removal and installation of radiator

radiator 1
Removal
rear frames.
ant. Wait until the coolant is cooled, and 7. Remove air conditioner receiver tank (8) and
then drain the coolant. bracket (9) together. [*1]


(1).
a Check that the covers are locked securely.
3. Open radiator grille (2).
8. Disconnect air aftercooler upper hose (10). [*2]

a Remove the air aftercooler upper hose
since it interferes with the air conditioner
condenser when the latter is removed.
9. Remove 4 mounting bolts (11) and air condi-

tioner condenser (12).
a Move air conditioner condenser (12) and
the air conditioner receiver tank to the
front of the machine.
4. Remove 4 bolts (3) and cover (4).

clamps (5).
6. Remove 4 bolts (6) on the right and left sides

and partition plate (7).
50-200 28 WA320, 320PZ-6

Removal and installation of radiator SEN04201-03
10. Disconnect radiator upper hose (13). [*3] 15. Remove 2 radiator mounting bolts (21) on the
top.
11. Remove 8 mounting bolts (15) on the right and
left sides and bracket (16).
16. Remove 2 bolts (19) and cover (20).

a This cover needs to be removed since it
12. Disconnect radiator lower hose (17). [*4] interferes with bolt (19) when the radiator
is removed.
13. Fix cooling fan and fan motor assembly (18)

open. 17. Remove radiator (22) from the left side. [*5]
a Check that the cooling fan and fan motor a When removing the radiator, take care not
assembly is locked securely. to damage the radiator core.
14. Remove 4 wiring harness clamps (14).
WA320, 320PZ-6 50-200 29

SEN04201-03 Removal and installation of radiator
Installation [*5]
q Carry out installation in the reverse order to a Fit grommet (23) to the mounting hole.
removal. a Check that projection (A) of the radiator is fit-
ted to grommet (23).
[*1] a When installing the radiator, set drain hose
3 Air conditioner receiver tank mounting U- (24) in mounting hole (B) securely.
clamp: 10.8 26.0 Nm {1.1 2.7 kgm}
[*2]
3 Air aftercooler upper hose clamp:
10.5 0.5 Nm {1.07 0.05 kgm}
[*3]
2 Radiator upper hose insertion area:
Gasket sealant
8.8 0.5 Nm {0.9 0.05 kgm}
[*4]
2 Radiator lower hose insertion area:
Gasket sealant
3 Radiator lower hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}

50-200 30 WA320, 320PZ-6

Removal and installation of air aftercooler SEN04201-03
Removal and installation of air 4. Remove upper 2 air aftercooler mounting bolts
aftercooler 1
(2).
Removal
rear frames.
5. Remove air aftercooler (3) from the left side.
1. Drain the coolant from the radiator. [*2]
a When removing the air aftercooler, take
care not to damage its core.
2. Remove the radiator. For details, see
Removal and installation of radiator.
3. Disconnect air aftercooler lower hose (1). [*1]

a Since the air aftercooler upper hose was
removed in Removal and installation of
radiator, it is not described here.
WA320, 320PZ-6 50-200 31

SEN04201-03 Removal and installation of air aftercooler
Installation
removal.
[*1]
3 Air aftercooler lower hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}
[*2]
a Fit grommet (4) to the mounting hole.
a Check that projection (A) of the air aftercooler
is fitted to grommet (4).

50-200 32 WA320, 320PZ-6

Removal and installation of hydraulic oil cooler assembly SEN04201-03
Removal and installation of 4. Disconnect hydraulic oil cooler lower hose (2).
hydraulic oil cooler assembly 1
a Plug the disconnected hose to prevent oil
leakage.
Removal
rear frames.
1. Drain the coolant from the radiator. 5. Remove 2 upper mounting bolts (3) of the
6
hydraulic oil cooler.
Radiator: Approx. 26 l
2. Remove the radiator. For details, see

Removal and installation of radiator.
3. Disconnect hydraulic oil cooler upper hose (1).

a Plug the disconnected hose to prevent oil
leakage.
6. Remove 2 lower mounting bolts (4) of the

hydraulic oil cooler.
WA320, 320PZ-6 50-200 33

SEN04201-03 Removal and installation of hydraulic oil cooler assembly
7. Remove 2 hydraulic oil cooler mounting bolts Installation

(5) on the right side. q Carry out installation in the reverse order to
removal.
q Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified
level. Run the engine to circulate the oil
through the system. Then, check the oil level
again.
5 Hydraulic oil (For details, see Table of
fuel, coolant and lubricants): Only nec-
essary quantity

8. Remove hydraulic oil cooler assembly (6) from specified level. Run the engine to circulate the
the right side. coolant through the system. Then, check the
a When removing, take care not to damage coolant level again.
5
the hydraulic oil cooler core. Total amount of coolant: 26.5 l
(For details, see Table of fuel, coolant
and lubricants)
50-200 34 WA320, 320PZ-6

Removal and installation of engine assembly SEN04201-03
Removal and installation of 4. Disconnect fuel prefilter wiring harness clamp

engine assembly 1
(2) and connector CN-E42 (3).
a The fuel prefilter assembly was removed
Removal and fixed in Removal and installation of
k Stop the machine on a level ground and set engine hood assembly.
rear frames.

5. Remove wiring harness clamp (4).
2. Remove the engine hood assembly. For 6. Disconnect alternator wiring harness terminals
details, see Removal and installation of CN-E02 (5) and CN-E03 (6).
7. Remove hose clamp (7).
a Remove the muffler cover since it will 8. Disconnect heater return hose (8).
interfere with the engine slings (wire
ropes, etc.)
WA320, 320PZ-6 50-200 35

SEN04201-03 Removal and installation of engine assembly
9. Remove wiring harness clamp (9). 15. Remove clamps (15) for the engine wiring har-
ness and air conditioner compressor hose.
10. Disconnect starting motor wiring harness ter-
minal (10).
16. Disconnect starting motor wiring (17).
11. Disconnect engine ground cable (11). [*1] 17. Disconnect wiring (18).
18. Disconnect connectors CN-ER1 (19), CN-ER2

(20) and CN-ER3 (21).
12. Remove hose clamp (12).
13. Disconnect heater inlet hose (13).
14. Remove engine wiring harness clamp (14).
50-200 36 WA320, 320PZ-6

19. Disconnect wiring harness connector (22). 21. Remove hose clamp (28).
22. Disconnect fuel return hose (29).
20. Remove the air conditioner compressor

assembly according to the following proce-
dure. 23. Remove 3 fan motor hose clamps (30).
1) Loosen air conditioner compressor
assembly mounting bolt (23).
2) Loosen air conditioner compressor drive
belt adjustment bolt (23a) and remove belt
(24). [*6]
24. Disconnect air aftercooler upper hose (31). [*2]
25. Disconnect radiator upper hose (32). [*3]
3) Disconnect wiring harness connector (25).

4) Remove bracket (26).
5) Remove air conditioner compressor
assembly (27).
WA320, 320PZ-6 50-200 37

26. Remove mounting brackets (33), then remove 29. Place bar [1] over the frame. Using lever
radiator hose lock bracket (34). blocks [3] and [2], sling HST pump assembly
(37) temporarily.
27. Disconnect air aftercooler lower hose (35). [*4]

30. Remove 12 damper cover mounting bolts (38).
28. Disconnect radiator lower hose (36). [*5] [*7]
a Do not remove HST pump mounting bolts
(39) to disconnect the HST pump.
q If the HST pump is disconnected from the
engine assembly, you cannot see if the
gears are meshed when installing the
engine assembly and the damper may be
damaged consequently.
50-200 38 WA320, 320PZ-6

31. Using the sling, lift up the engine assembly

temporarily.
32. Remove right and left engine mounting bolts

(40) at the rear of the machine. [*8]
Installation
removal.
33. Remove right and left engine mounting bolts
[*1]
3
(41) at the front of the machine. [*9]
Engine ground cable mounting bolt:
98 123 Nm {10.0 12.5 kgm}
34. Remove each 4 engine mounting bolts (42) on
the right and left side of the front of the
[*2]
3
machine to remove bracket (43). [*10]
Air aftercooler upper hose clamp:
a Loosen adjustment bolts (43a) and (43b).
10.5 0.5 Nm {1.07 0.05 kgm}
[*3]
2 Radiator upper hose: Gasket sealant
8.8 0.5 Nm {0.9 0.05 kgm}
[*4]
3 Air aftercooler lower hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}
[*5]
2 Radiator lower hose: Gasket sealant
35. Lift up engine assembly (44) a little and move it 3 Radiator lower hose clamp:
toward the rear of the machine to disconnect it 8.8 0.5 Nm {0.9 0.05 kgm}
from the HST pump assembly. [*11]
[*6]
36. Lift off engine assembly (44). Adjust the air conditioner compressor belt tension.
a Check that all the electric wiring and For details, see Testing and adjusting, Adjusting
hydraulic piping are disconnected. air conditioner compressor belt tension.
a When removing the engine, take care that
it will not interfere with the radiator, air [*7]
aftercooler and hydraulic oil cooler. 2 Damper cover mating face:
4 Engine assembly: 700 kg Gasket sealant (LG-6)
3 Damper cover mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}
WA320, 320PZ-6 50-200 39

[*8]
3 Right and left engine mounting bolts (40) at
rear of machine:
245 308.9 Nm {25.0 31.5 kgm}
[*9]
3 Right and left engine mounting bolts (41) at
front of machine:
245 308.9 Nm {25.0 31.5 kgm}
[*10]
3 Right and left engine mount bracket mount-
ing bolts (42) at front of machine:
98 123 Nm {10.0 12.5 kgm}
a Adjust clearances (a) and (b) of right and left
engine mount adjustment bolts (43a) and (43b) q Bleeding air
at front of machine to the following dimensions Bleed air from the fuel system. For details, see
and lock the adjustment bolts. Testing and adjusting, Bleeding air from fuel
Clearance (a): 2 mm circuit.
Clearance (b): 2 mm
[*11]
a When installing the engine assembly, carefully
set damper flange (45) to the gear of HST
pump boss (46).
a Take care not to damage flange (45).
50-200 40 WA320, 320PZ-6

Removal and installation of engine front oil seal assembly SEN04201-03
Removal and installation of 2. Remove 4 bolts (2), then remove cover (3).
engine front oil seal assembly 1
Special tools clamps (4).
New/Remodel
4. Remove 4 bolts (5) on the right and left sides,
Necessity
Sketch
then remove partition plate (6).
Q'ty
1 795-799-6400 Seal puller t 1

A
6 790-331-1120 Wrench (angle) q 1
Removal
rear frames.
k Disconnect the cable from the negative () 5. Remove cover (7).

(1).
WA320, 320PZ-6 50-200 41

SEN04201-03 Removal and installation of engine front oil seal assembly
6. Put wrench [1] in the concave section (width 8. Remove engine front oil seal (12).
across flats: 12.7 mm) of tensioner assembly
(8) and turn it in the unwinding direction to
decrease the tension of fan belt (9).
k Set the wrench [1] securely to the con-
cave section of tensioner assembly (8)
before turning it. (The spring of ten-
sioner assembly (8) is strong. If the
wrench [1] is set incompletely and
turned, it comes off and that is very
dangerous.)
k After removing fan belt (9), return ten-
sioner assembly (8) slowly and care-
fully.
k Take care not to catch your finger
between the pulley and fan belt (9) dur-
ing work.
Installation
1. Using tool A1, install engine front oil seal (12).
a Before installing the engine front oil seal,
check that crankshaft end corners and
seal lip sliding surfaces are free from a
housing flaw, burr, fin, rust, etc.
a Before installing the engine front oil seal,
degrease, clean, and dry the seal contact
faces of the crankshaft and the seal lip
surfaces to prevent oil leakage.
a When installing the engine front oil seal,
do not apply oil or grease to the crankshaft
and seal lip.
7. Remove 6 mounting bolts (10) and vibration

damper (11).
50-200 42 WA320, 320PZ-6

Removal and installation of engine front oil seal assembly SEN04201-03
a The extrusion and runout of engine front oil a When not using angle tightening tool
seal (12) from cover (13) must be within the 5] After steps 1] 3], make marks on the
following range. vibration damper and each bolt with a
q Extrusion (x): Max. 0.38 mm paint.
q Facial runout (TIR: Total Indicator Reading) (y): 6] Tighten the bolts by 90 5.
Max. 0.25 mm
q Carry out the following installation in the

2. Vibration damper reverse order to removal.
1) Install vibration damper (8) to the crank-
shaft while setting the dowel hole of the
former to dowel pin (a) of the latter.
2) Tighten mounting bolts (7) according to
1] Tighten the bolts to 55 5 Nm {5.6
0.5 kgm} in the diagonal order.
2] Loosen the bolts by 180.
3] Tighten the bolts to 55 5 Nm {5.6
0.5 kgm} in the diagonal order.
4] Retighten the bolts by 90 5.
a Tool A6 (wrench) is set for angle
tightening. (See the Special tools
list.)
WA320, 320PZ-6 50-200 43

SEN04201-03 Removal and installation of engine rear oil seal assembly
Removal and installation of 5. Install eyebolt [1] to the damper mounting bolt
engine rear oil seal assembly 1
hole and sling flywheel assembly (4).
Special tools 6. Remove the 2 flywheel mounting bolts and

install guide bolts [2].
New/Remodel
Necessity
Sketch
7. Remove other 6 mounting bolts (3) and lift off
Q'ty
Symbol Part No. Part name flywheel assembly (4). [*2]
4 Flywheel assembly: 45 kg
A 2 795-799-6500 Seal puller t 1
Removal
rear frames.
ant. Wait until the coolant is cooled, and 8. Engine rear oil seal
then drain the coolant. 1) Install tool A2 to the crankshaft.
2) Tighten tapping screw [3] of tool A2 into
1. Drain the coolant from the radiator. the seal carrier of engine rear oil seal (5).
6 Radiator: Approx. 26.5 l 3) Rotate the wrench handle clockwise to
remove engine rear oil seal (5).

3. Remove the engine assembly. For details, see

Removal and installation of engine assembly.
4. Remove 8 mounting bolts (1) and damper

flange (2). [*1]
50-200 44 WA320, 320PZ-6

Removal and installation of engine rear oil seal assembly SEN04201-03
Installation
1. Keep pilot [4] installed to engine rear oil seal

(5) until it is inserted in the crankshaft.
a Before installing the engine rear oil seal,
check that crankshaft end corners and
seal lip sliding surfaces are free from
housing flaw, burr, fin, rust, etc.
a Before installing the engine rear oil seal,
degrease, clean, and dry the seal contact
faces of the crankshaft and the seal lip
surfaces to prevent oil leakage.
a When installing the engine rear oil seal, do
not apply oil or grease to the crankshaft
and seal lip.
q Carry out the following installation in the

2. Insert pilot [4] in crankshaft (6) and push reverse order to removal.
engine rear oil seal (5) into flywheel housing
(7). [*1]
a When installing damper flange (2), direct part
3. Push in engine rear oil seal (5) further and then (a) as shown below.
pull out pilot [4].
2 Damper flange mounting bolt (1):

4. Using tool A2, install engine rear oil seal (5) to Adhesive (LT-2)
flywheel housing (7). 3 Damper flange mounting bolt (1):
a When installing engine rear oil seal (5), 44.1 53.9 Nm {4.5 5.5 kgm}
take care not to bend it.
a Extrusion of engine rear oil seal (5) (x):
Max. 0.38 mm
WA320, 320PZ-6 50-200 45

SEN04201-03 Removal and installation of engine rear oil seal assembly
[*2] q Measuring facial runout

a Tighten 8 flywheel assembly mounting bolts in a Facial runout: Max. 0.20 mm
the following order. 1) Install the stand to dial gauge [6] and
a Using a bar, lock the flywheel. install them to flywheel housing (7).
3 Flywheel mounting bolt: 2) Set the dial gauge so that its probe will be
137 7 Nm {13.97 0.71 kgm} perpendicular to face end (c) of the fly-
wheel near the periphery.
3) Rotate the flywheel by 1 turn and measure
the difference between the lowest and
highest values indicated by the dial gauge.
a After rotating the flywheel by 1 turn, check that
the dial gauge indicates the value at the start
of rotation.
q Measuring radial runout

a Radial runout: Max. 0.13 mm
1) Install the stand to dial gauge [6] and
install them to flywheel housing (7).
2) Set the dial gauge so that its probe will be
perpendicular to spigot portion (b) or
periphery of the flywheel.
q Bleeding air
circuit.

3) Rotate the flywheel by 1 turn and measure

the difference between the lowest and
highest values indicated by the dial gauge.
a After rotating the flywheel by 1 turn,
check that the dial gauge indicates
the value at the start of rotation.
50-200 46 WA320, 320PZ-6

Removal and installation of cooling fan and fan motor assembly SEN04201-03
Removal and installation of 3. Remove 4 breather hose clamps (3) of fuel

cooling fan and fan motor tank.
assembly 1
4. Remove clip (5) and disconnect hose (4) of
Special tools fuel tank from breather (6).
New/Remodel
5. Remove breather (6).
Necessity
Sketch
Q'ty
A 8 791-415-2002 Remover q 1
Removal
rear frames.
terminal of the battery. 6. Remove 3 wiring harness clamps (7).
1. Open radiator grille (1). 7. Disconnect wiring harness connectors CN-R59

(8) and CN-R29 (9).
8. Disconnect P port hose (10), TC port hose (11)

and T port hose (12).
a Plug the disconnected hoses and ports to
prevent oil leakage.
2. Remove cover (2).
WA320, 320PZ-6 50-200 47

SEN04201-03 Removal and installation of cooling fan and fan motor assembly
9. Move the lock portion of stopper link (13) to 12. Remove 4 mounting bolts (19) and remove fan
hole (A) of bracket (14) to remove it from the motor assembly (21) from bracket (20). [*3]
bracket.
10. Remove mounting bolt (16), stopper plate (15)

Installation
and nut (17). [*1]
removal.
[*1]
3 Nut (17): 98 127.5 Nm {10 13 kgm}
a Set the installed position of stopper plate (15)
in the tightening direction of nut (17).
2 Mounting bolt (16): Adhesive (LT-2)
3 Mounting bolt (16):
59 74 Nm {6 7.5 kgm}
[*2]
a Check that key (22) is fitted securely to the key
way on the shaft of fan motor assembly (21).
a When installing cooling fan assembly (18), set
11. Using tool A8, remove cooling fan assembly its key way to key (22).
(18). [*2]
50-200 48 WA320, 320PZ-6

Removal and installation of cooling fan and fan motor assembly SEN04201-03
[*3]
a Before installing fan motor assembly (21), add
hydraulic oil from port (23) (for details, see
Table of fuel, coolant and lubricants) until it
flows over and then install the plug.

again.
essary quantity
WA320, 320PZ-6 50-200 49

SEN04201-03 Removal and installation of fuel tank assembly
Removal and installation of fuel 6. Disconnect fuel level gauge wiring harness
tank assembly 1
connector CN-R21 (7).
Removal 7. Remove hose clamp (8).

the lock bar to the frame to fix the front and 8. Disconnect fuel return hose (9) and supply
rear frames. hose (10).
k Lower the work equipment to the ground, a Plug the disconnected hoses to prevent
stop the engine, apply the parking brake, fuel leakage.
1. Drain the fuel from the fuel tank.

6 Fuel tank: 245 l (When full)

(1).
3. Open radiator grille (2).
9. Remove power train oil cooler hose clamp (11)

under the front of the radiator.
4. Remove 4 breather hose clamps (3) of the fuel

tank.
5. Remove clip (5) and disconnect hose (4) from

10. Remove hydraulic oil cooler hose clamps (12)
breather (6).
and (13) under the front of the hydraulic oil
cooler.
50-200 50 WA320, 320PZ-6

Removal and installation of fuel tank assembly SEN04201-03
11. Support the fuel tank bottom with the transmis- Installation
sion jack. q Carry out installation in the reverse order to
removal.
12. Remove fuel tank front mounting bolts (14) on
the right and left sides. [*1] [*1], [*2]
3 Fuel tank mounting bolts (14) and (15):
245 309 Nm {25.0 31.5 kgm}
q Refilling with fuel (Fuel tank)

5 Fuel: 245 l (When full)
13. Remove fuel tank rear mounting bolt (15) from

the counterweight bottom. [*2]
14. Lower transmission jack [1] gradually and

remove fuel tank assembly (16).
a Take care extremely that the fuel tank will
not come off from the transmission jack.
4 Fuel tank assembly:
130 kg (excluding fuel)
WA320, 320PZ-6 50-200 51

SEN04201-03

2010 KOMATSU
All Rights Reserved
50-200 52
SEN04202-00
WA320-6
WA320PZ-6
WA320-6 70001 and up

310 Power train, Part 1

Removal and installation of transfer assembly ............................................................................................... 2
Disassembly and assembly of transfer assembly ........................................................................................... 5
Removal and installation of parking brake assembly .................................................................................... 24
Disassembly and assembly of parking brake assembly ............................................................................... 25
WA320, 320PZ-6 50-310 1

SEN04202-00 Removal and installation of transfer assembly
Removal and installation of 5. Disconnect motor 1 drain hose (1) and motor 2
transfer assembly 1
drain hose (2).
Removal
rear frames.
k Press the brake pedal at least 100 times to
release the residual pressure in the brake
accumulator circuit.
q Precautions for handling refrigerant 6. Disconnect accumulator charge valve drain

k Collect refrigerant (R134a) beforehand. hose (3).
a Ask professional traders for collecting and
filling the refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant (R134a) gets inside
ones eyes, it may cause blindness.
Therefore, make sure to wear protec-
tive glasses when collecting or filling
the refrigerant. Collecting and filling
work must be conducted by a qualified
person.
k If the radiator coolant temperature is
high, you may scald yourself with the
hot coolant when disconnecting the
heater hoses and draining the coolant.
7. Disconnect PA-port hose (4) and PB-port hose
Wait until the coolant is cooled, and
(5) from the brake valve.
8. Disconnect clutch valve P-port hose (6).
1. Recover the refrigerant (R134a). [*1]
9. Disconnect transfer cooler hose (7).
3. Remove the operator's cab assembly. For

details, see Removal and installation of opera-
tor's cab.
4. Remove the HST pump and 4-gear pump

assembly. For details, see Removal and
installation of HST pump and 4-gear pump
assembly.
50-310 2 WA320, 320PZ-6

Removal and installation of transfer assembly SEN04202-00
10. Disconnect clamps (8), (9), and (10). 13. Sling the transfer assembly temporarily and
remove 2 transfer cushions (13) on right and
left sides. [*4]
14. remove the 2 transfer mounting bolts on right

and left sides. [*5]
a After removing the right cushion, remove
accumulator and bracket assembly (14).
11. Disconnect front drive shaft (11) from the trans-

fer side. [*2]
15. Remove the 2 mounting bolts and bracket (15).
12. Remove rear drive shaft (12). [*3]
16. Lift off transfer assembly (16).

a Check that all the wires and pipes are dis-
connected, and then sling the assembly
slowly.
4 Transfer and HST motor assembly:
420 kg
WA320, 320PZ-6 50-310 3

SEN04202-00 Removal and installation of transfer assembly
Installation [*4]
q Carry out installation in the reverse order to 3 Transfer cushion mounting bolt:
removal. M10 bolt: 59 74 Nm {6.0 7.5 kgm}
M12 bolt: 98 123 Nm {10.0 12.5 kgm}
[*1]
a When installing the hoses of the air conditioner [*5]
circuit, take care that dirt, dust, water, etc. will 3 Transfer mount mounting bolt:
not enter them. 610 765 Nm {62.5 78.0 kgm}
a When installing each air conditioner hose,
check that O-ring (17) is fitted to it.
a Check O-ring (17) for a flaw and deterioration. q Refilling with oil (Hydraulic tank)
a When connecting each refrigerant pipe, apply Add oil through the oil filler to the specified
compressor oil for new refrigerant (R134a) level. Run the engine to circulate the oil
(DENSO: ND-OIL8 or ZEXEL ZXL100PG through the system. Then, check the oil level
(equivalent to PAG46)) to O-ring (17). again.
5
3
Hydraulic oil (for details, see Table of
Threaded part of hose (M16 1.5):
12 15 Nm {1.2 1.5 kgm}
essary quantity
3 Threaded part of hose (M22 1.5):
20 25 Nm {2.0 2.5 kgm} q Refilling with coolant
3 Threaded part of hose (M24 1.5): specified level. Run the engine to circulate the
30 35 Nm {3.0 3.5 kgm} coolant through the system. Then, check the
q Charging with refrigerant (R134a)

Charge the air conditioner circuit with refriger-
ant (R134a).
[*2], [*3]
3 Drive shaft mounting bolt:
59 74 Nm {6.0 7.5 kgm}
a Precautions for installing rear drive shaft

1) Check that the key of the spider cap is fit-
ted to the key way of the mating yoke and
then tighten the mounting bolts.
2) Check that the lateral runout of the rear
axle and transfer from each other is 3 mm
or less.
3) If the runout in 2) is 3 mm or larger, adjust
the transfer cushion and transfer mount to
reduce the runout.
50-310 4 WA320, 320PZ-6

Disassembly and assembly of transfer assembly SEN04202-00
Disassembly and assembly of Disassembly

transfer assembly 1 1. Transfer assembly
Drain the transfer oil.
Special tools
6 Transfer oil: 7.2 l
New/Remodel
Necessity
Sketch
2. Brake accumulator
Q'ty
1) Remove the speed sensor from the trans-
fer case top.
2) Disconnect wiring connectors T06 (1) and
1 790-201-2840 Spacer t 1
T11 (2).
2 793T-417-1110 Push tool t 1 Q
790-101-5311 Plate 1
3
790-101-5221 Grip 1
01010-51225 Bolt 1
793T-417-1120 Push tool t 1 Q
4 790-101-5221 Grip t 1
01010-81225 Bolt t 1
5 799-301-1500 Oil leak tester t 1
6 799-401-3200 Adapter t 1
7 02789-00315 Cap t 1
8 799-101-5160 Nipple t 1
3) Disconnect wiring connectors T10 (3) and
9 790-190-1500 Pump assembly t 1
T07 (4).
10 790-201-3260 Bolt q 2
(12 x 1.75 mm)
11 792-735-2420 Collar t 1
D
12 792-104-1130 Collar t 1
14 790-101-2501 Puller q 1
15 790-102-2900 Puller q 1
16 790-201-1320 Spacer t 1
17 790-101-3501 Gear puller q 1
19 79G-17L-1000 Bar t 1
20 795-100-1291 Sleeve driver t 1
21 796-430-1110 Push tool t 1 4) Disconnect clutch port hose (5).
22 790-470-1410 Collar t 1 5) Remove the 6 mounting bolts and bracket
assembly (6).
23 796-667-1310 Collar t 1
24 79G-05V-1400 Bar t 2
25 791-126-0211 Adapter t 1
Commercially
26 available Torque wrench q 1
27 790-434-1470 Push tool q 1
WA320, 320PZ-6 50-310 5

SEN04202-00 Disassembly and assembly of transfer assembly
3. HST motor 3) Remove the mounting bolts. Using tool

1) Remove the 4 mounting bolts and lift off D10, remove parking brake assembly
HST motor 1 (7). (15).
2) Remove the 4 mounting bolts and lift off a For disassembly and assembly of the
HST motor 2 (8). parking brake assembly, see Disas-
sembly and assembly of parking
brake assembly.
4. Oil supply pipe and hose

1) Remove oil supply pipe (9).
2) Remove hose (10) from the transfer case 6. Hub
strainer. 1) Remove snap ring (16).
2) Remove hub (17).
5. Parking brake assembly

1) Set the transfer assembly to a block with
the parking brake side up.
2) Remove coupling (14) on the parking
brake side.
50-310 6 WA320, 320PZ-6

7. Belleville springs 3) Remove 7 belleville springs (19).

1) Turn over the case and remove cage (18) a Check the directions of the belleville
from the HST motor 1 mounting section. springs.
a Loosen the mounting bolts evenly a The 1st belleville spring (The one on
and gradually to release the belleville the top) has a yellow mark.
springs, and then remove the cage. a When any belleville spring needs to
q Free height of belleville springs be replaced, replace all of the 7
(7-piece set): 57.4 mm springs as a set.
q Installed height of belleville
springs (7-piece set): 44.8 mm
q Installed load of belleville springs
(7-piece set): 21,500 N {2,190
kg}
8. Piston and spacer

1) Remove piston (20).
2) Remove snap ring (89).

Using tool D25, remove bearing (88).
2) Put copper plate [1] in the O-ring groove

and remove spacer (21) with a flat-head
screwdriver.
WA320, 320PZ-6 50-310 7

9. Clutch discs, plates, and springs 11. Cage assembly

1) Remove 7 discs (22), 8 plates (23), and 7 1) Remove the mounting bolts. Using tool
wave springs (24). D10, remove cage assembly (28).
2) Remove end plate (25). 2) Remove shims (29).

a Check the thickness and quantity of
the shims.
10. Coupling
1) Remove the mounting bolts and holder
(26). 3) Remove dust seal (30) and oil seal (31)
2) Remove coupling (27). from cage (32).
4) Remove outer race (33).
50-310 8 WA320, 320PZ-6

12. Spacer 15. Disassembly of HST motor 1 shaft and ring

Remove spacer (34). gear assembly
1) Remove snap ring (37) and sun gear (38).
13. Front case

Remove the mounting bolts. Using tool D10 2) Remove snap ring (39).
and screwdrivers, remove front case (35).
a Take care not to forget to remove the bolts
on the rear case side (5 pieces).
a When using screwdrivers, take care not to
scratch the case mating face.
3) Supporting ring gear (40) and using tool

D11 and a press, push out HST motor 1
shaft (41).
14. Removal of HST motor 1 shaft and ring gear

Remove HST motor 1 shaft and ring gear
assembly (36).
WA320, 320PZ-6 50-310 9

4) Remove bearing (42) and spacer (43) 3) Using tool D13, remove front bearing (53).
from ring gear (40).
5) Remove snap ring (44) and bearing (45).
18. Removal of carrier assembly

1) Remove 6 bolts (54).
16. Removal of output shaft and gear assembly 2) Using tool D14, remove carrier assembly
1) Remove 2 mounting bolts (47) of cover (55).
(46).
2) Remove output shaft and gear assembly
(49) and cover (46).
19. Disassembly of carrier assembly

1) Remove shaft (56) and ball (57) from car-
rier (58).
17. Disassembly of output shaft and gear a Keep the ball carefully.
assembly 2) Remove 2 thrust washers (59), planetary
1) Using tool D12, remove rear bearing (50). gear (60), and bearing (61) (at 3 places).
2) Remove gear (51) and spacer (52).
50-310 10 WA320, 320PZ-6

20. Holder 22. Disassembly of HST motor 2 gear and bear-

1) Remove mounting bolt (62) and holder ing assembly
(63). 1) Using puller D15 and tool D16, remove 2
bearings (69) from HST motor 2 gear (68).
2) Remove seal rings (64) and (65) and O- 23. Removal of HST motor 1 gear and outer
ring (66) from holder (63). races
Do not remove HST motor 1 gear shaft (70). (If
it is removed forcibly and reused, it can cause
a trouble.)
1) Using puller D17, remove bearing (71)
and HST motor 1 gear (72).
21. Removal of HST motor 2 gear and bearing

assembly
Remove HST motor 2 gear and bearing
assembly (67).
a If the claws of puller D17 are so thick
that they cannot be inserted between
the gear and case, screw 3 bolts [2]
(M14) into the carrier mounting holes
of HST motor 1 gear (72) by 15 mm.
Then, using 3-claw puller D17,
remove bearing (71) and HST motor
1 gear (72).
WA320, 320PZ-6 50-310 11

24. Disassembly of HST motor 1 gear and outer 26. Rear case
races Remove outer race (80) from rear case (79).
1) Using puller D18, remove 2 outer races
(73) from HST motor 1 gear (72), and then
remove spacer (74).
2) Remove seal ring (75).
27. Clutch housing

1) Using tool D20, remove clutch housing
(81) and 3 pins (82).
2) Remove snap ring (83) from clutch hous-
25. Bearing ing (81).
1) Remove 2 plugs (76) from shaft (70). 3) Remove snap ring (84).
2) Remove spacer (77).

3) Insert 2 tools D19 in the plug holes and hit
them evenly to remove bearing (78) from
shaft (70).
a Do not remove shaft (70).
50-310 12 WA320, 320PZ-6

Assembly 3. Installation of HST motor 2 gear and bear-

a Clean the all parts and check them for dirt or ing assembly
damage. Coat their sliding surfaces with power Install HST motor 2 gear and bearing assembly
line oil (TO10) before installing. (67).
a Before icing a bearing in dry ice for expansion
fit, drop about 6 cc of power line oil (TO10)
onto it and rotate it 10 turns.
1. Rear case
Press fit outer race (80) of the output shaft to
rear case (79).
4. Assembly of HST motor 1 gear and outer

races
1) Install spacer (74) to HST motor 1 gear
(72).
2) Using tool D22, press fit 2 outer races (73)
to HST motor 1 gear (72).
3) Install seal ring (75) to HST motor 1 gear
2. Assembly of HST motor 2 gear and bearing (72).
assembly 3 Seal ring: Grease (G2-LI)
Using push tool D21, press fit 2 bearings (69)

to HST motor 2 gear (68).
a After press fitting the bearings, apply
transfer oil to them and rotate them.
5. Bearing and HST motor 1 gear

1) Using tool D23 and the press, press fit
bearing (78).
WA320, 320PZ-6 50-310 13

2) Install spacer (77). 2) Install holder (63) and tighten the mount-
ing bolt.
a Set the hole 2 mm in diameter (g) on
the top of the holder horizontally [Set
it at 90 to the hole 4.5 mm in diame-
ter (h) on shaft (70)].
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
88.2 107.8 Nm {9 11 kgm}
3) Install HST motor 1 gear (72).

4) Using push tool D21 and the press, press
fit bearing (71).
q Projection of bearing from shaft:
0.92 2.13 mm
7. Assembly of carrier assembly

1) Set planetary gear (60), bearing (61), and
2 thrust washers (59) to carrier (58) (at 3
places).
2) Install pinion shaft (56) to carrier (58),
matching their ball holes to each other,
and then install ball (57).
6. Holder
1) Install seal rings (64) and (65) and O-ring
(66) to holder (63).
2 Seal ring and O-ring:
Grease (G2-LI)
50-310 14 WA320, 320PZ-6

8. Installation of carrier assembly 3) Install spacer (43) and set bearing (42).
1) Install carrier assembly (55), matching it to a Take care of the setting direction of
the dowel pin of the HST motor 1 gear. the bearing (flanged).
2) Tighten mounting bolts (54).
3 Mounting bolt:
137 196 Nm {14 20 kgm}
4) Using push tool D21 and the press, press

fit bearing (42).
9. Assembly of HST motor 1 shaft and ring

gear assembly
1) Install bearing (45) to ring gear (40), and
then install snap ring (44).
5) Install snap ring (39).
2) Set ring gear (40) to HST motor 1 shaft

(41). Using push tool D21 and the press,
press fit bearing (45).
WA320, 320PZ-6 50-310 15

6) Install sun gear (38) and snap ring (37). 2) Rotate the shaft and set spacer (52).
3) Install output gear (51).
2 Gear spline: Grease (LM-G)
10. Installation of HST motor 1 shaft and ring

gear
Install HST motor 1 shaft and ring gear assem- 4) Using tool D2 and the press, press fit rear
bly (36). bearing (50).
a After press fitting the bearing, apply
transfer oil to it and rotate it.
11. Assembly of output shaft and gear assem-

bly
1) Using tool D1 and the press, press fit front
bearing (53) until it touches output shaft
(85).
a After press fitting the bearing, apply
transfer oil and rotate it.
50-310 16 WA320, 320PZ-6

12. Installation of output shaft and gear assem- 14. Front case
bly a Use the front case and rear case as an
1) Put cover (46) over the gear and install assembly.
output shaft and gear assembly (49) to the a When installing the cases, match the
rear case. match marks on their tops to each other.
2) Secure cover (46) with bolts (47). 1) Apply gasket sealant to the rear case
a Check that cover (46) does not inter- according to the following procedure.
fere with the inside of the gear. a Apply the gasket sealant to forcing
2 Mounting bolt: Adhesive (LT-2) screw contact part (a), similarly to the
3 Mounting bolt: dimensions for each bolt hole.
98 123 Nm {10 12.5 kgm} a Apply the gasket sealant so that
dimensions (b) and (c) will be the
same respectively.
a Apply the gasket sealant so that
dimension (e) x dimension (f) will be 2
5 mm.
2 Gasket sealant:
ThreeBond 1207B or equivalent
13. Clutch housing

1) Install snap ring (84) to the front case.
2) Install clutch housing (81) and 3 pins (82).
2) Set tool D24 and install front case (35).

3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
3) Install snap ring (83)
WA320, 320PZ-6 50-310 17

3) Install snap ring (86) on the HST motor 2 2) Install 7 discs (22), 7 wave springs (24),
side. and 8 plates (23).
a Soak the discs in clean transfer oil for
at least 2 minutes before installing
them.
4) Install spacer (34) of the output shaft.
16. Spacer and piston

1) Install the O-ring and spacer (21).
2 O-ring: Grease (G2-LI)
15. Clutch discs, plates, and springs

1) Install end plate (25).
2) Install the O-ring and piston (20).

2 O-ring: Grease (G2-LI)
50-310 18 WA320, 320PZ-6

17. Belleville springs 18. Cage

1) Set the 1st one (bottom one) of the 7 1) Install cage (18).
belleville springs (19) with the convex side a Tighten the mounting bolts evenly
up. and gradually.
2) Set the 2nd, 4th, and 6th belleville springs q Installed load of belleville springs
in the opposite direction to the 1st one and (7-piece set): 21,500 N {2,190 kg}
set the 3rd and 5th ones in the same 3 Mounting bolt:
direction as the 1st one. (There are no 245 308 Nm {25 31.5 kgm}
marks on the 1st 6th springs.) 2) After installing cage (18), press fit bearing
3) Set the 7th belleville spring with the yellow (88) with tool D25 and install snap ring
mark side up. (89).
a When any belleville spring needs to
be replaced, replace all of the 7
springs as a set.
WA320, 320PZ-6 50-310 19

19. Operation test of transfer clutch 21. Adjusting pre-load on output shaft taper
Using tool D5, apply oil pressure to transfer roller bearing
clutch disengagement port (m). 1) Install cage (28) without inserting any
a When the oil pressure is applied, if the shim.
transfer clutch is disengaged, it is operat- 3 Mounting bolt:
ing normally. 4.80 0.98 Nm {0.5 0.1 kgm}
q Clutch disengaging oil pressure: 2) Rotate the output shaft by 20 turns and
1.52 MPa {15.5 kg/cm2} check the tightening torque of the mount-
ing bolts tightened in step 1).
a If the tightening torque has changed,
repeat steps 1) and 2), and then
check again.
3) If the tightening torque has not changed,
measure the clearances at 3 places (j) of
cage (28) and obtain average (k).
a To confirm that the bearing is not
leaning, check that the dispersion of
clearances at 3 places (j) is 0.15 mm
or less. If the dispersion is large, the
bearing is not installed normally or
there is another cause. In this case,
eliminate the cause and reduce the
20. Cage assembly dispersion to 0.15 mm or less.
1) Press fit outer race (33) to cage (32).
2) Using tools D3 and D4, press fit oil seal
(31) and dust seal (30) to cage (32).
2 Lips and clearances of oil seal and
dust seal: Silicone grease (Three-
Bond 1855 or equivalent)
50-310 20 WA320, 320PZ-6

4) Calculate shim thickness (t). 22. Coupling

q Shim thickness (t) = Average of clear- 1) Install coupling (27) on the cage side.
ance (k) + 0.15 mm to 0.20 mm 2 Spline of coupling: Lubricant con-
5) Insert selected shim (29) between cage taining molybdenum disulfide
assembly (28) and the front case. (LM-G)
6) Tighten the cage mounting bolts. 2) Install holder (26) and tighten the mount-
3 Mounting bolt: ing bolt.
98 123 Nm {10.0 12.5 kgm} 2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
7) Install holder (26) and the holder mounting

bolt to the output shaft.
8) Set tool D26 to the holder mounting bolt 23. Hub
and measure the rotating torque of the 1) Turn over the transfer assembly and install
output shaft. hub (17).
a Measure the rotating torque without 2) Install snap ring (16).
installing the front and rear couplings. 2 Spline of output shaft: Lubricant
q Rotating torque of output shaft: containing molybdenum disul-
4.9 6.7 Nm {0.5 0.7 kgm} fide (LM-G)
WA320, 320PZ-6 50-310 21

24. Parking brake assembly 25. Coupling

1) Remove 2 dowel pins (87) from the park- Install coupling (14).
ing brake assembly. 2 Spline of coupling: Lubricant contain-
a The dowel pins may be left on the ing molybdenum disulfide (LM-G)
transfer case side.
26. Oil supply pipe and hose

2) Install parking brake assembly (15). 1) Connect hose (10) to the transfer case
a After the all internal teeth of the disc strainer.
are meshed with the spline and the 2) Install oil supply pipe (9).
clearance between the parking brake
housing and transfer case is elimi-
nated, tighten the mounting bolts.
a If the mounting bolts are tightened
while there is clearance between the
parking brake housing and transfer
case and the internal teeth of the disc
are shifted from the spline, the disc
will be broken. Accordingly, remove
the dowel pins and check securely in
advance that there is not clearance.
a Do not reuse the gasket but fit new
one to the case side.
3) Drive in the dowel pins and tighten the
mounting bolts. 27. HST motor
3 Mounting bolt: 1) Sling and install HST motor 2 (8).
98 123 Nm {10.0 12.5 kgm} 2 Spline of HST motor 2: Lubricant
containing molybdenum disul-
fide (LM-G)
3 Mounting bolt:
245 309 Nm {25.0 31.5 kgm}
2) Sling and install HST motor 1 (7).
a Do not apply LM-G to the spline of
HST motor 1.
3 Mounting bolt:
245 309 Nm {25.0 31.5 kgm}
50-310 22 WA320, 320PZ-6

4) Connect wiring connectors T06 (1) and

T11 (2).
28. Transfer oil filter

1) Install transfer oil filter bracket assembly
(6) with the 6 mounting bolts. 5) Install the speed sensor to the transfer
2) Connect clutch port hose (5). case top.
3) Connect wiring connectors T10 (3) and

T07 (4).
WA320, 320PZ-6 50-310 23

SEN04202-00 Removal and installation of parking brake assembly
Removal and installation of 6. Disconnect transfer lubricating oil pump hose

parking brake assembly 1
(9).
Removal 7. Remove the parking brake mounting bolts.

k Stop the machine on a level ground and set Then, using tool D10, remove parking brake
the lock bar to the frame to fix the front and assembly (10). [*3]
rear frames.
k Keep in mind that the parking brake is
removed = you cannot apply the parking
brake.
1. Turn the parking brake OFF (Release it).
2. Drain the transfer oil.

6 Transfer case: 7.2 l
3. Remove cotter pin (2) and pin (3) of the park-

ing brake cylinder. [*1]
a The parking brake cylinder is at the front Installation
of the inside of the left rear wheel. q Carry out installation in the reverse order to
removal.
4. Remove rear drive shaft (7). [*2]
[*1]
5. Remove coupling (8). a After inserting cotter pin (2) in pin (3), open it to
180.
[*2]
3 Rear drive shaft mounting bolt:
59 74 Nm {6.0 7.5 kgm}
a Precautions for installing rear drive shaft

1) When installing the drive shaft, check that
the key way of the spider cap is fitted in
the key way of the mating yoke, and then
tighten the mounting bolts.
2) When installing the rear drive shaft, check
that misalignment between the rear axle
and transfer in the lateral direction is not
larger than 3 mm.
3) If misalignment checked in 2) is larger
than 3 mm, adjust the positions of the
transfer cushion and transfer mount.
[*3]
a Using guide bolts, install the parking brake.
3 Parking brake mounting bolt:
98 123 Nm {10.0 12.5 kgm}
q Refilling with oil (Transfer case)

again.
6 Transfer case: 7.2 l
50-310 24 WA320, 320PZ-6

Disassembly and assembly of parking brake assembly SEN04202-00
Disassembly and assembly of 2. Plates, discs, and springs

parking brake assembly 1
1) Remove 2 clamping bolts (3) and 2 spac-
ers (4).
Special tools a Since the spring tension is applied,
loosen the 2 clamping bolts evenly.
New/Remodel
Necessity
Sketch
Sym-
Q'ty
Part No. Part Name
bol

790-101-5301 Plate 1
3
790-101-5221 Grip 1
D 01010-51225 Bolt 1
793T-417-1120 Push tool t 1 Q
4 790-101-5221 Grip t 1
01010-81225 Bolt t 1
2) Remove 5 plates (5), 4 wave springs (6),
and 4 discs (7).
Disassembly
1. Strainer
1) Remove cover (1).
3. Cam plate
Remove cam plate (8).
2) Remove strainer (2).
WA320, 320PZ-6 50-310 25

SEN04202-00 Disassembly and assembly of parking brake assembly
4. Ball 6. Pin
Remove 6 balls (9). Remove pin (12).
7. Dust seal and oil seal

Remove dust seal (13) and oil seal (14).
5. Lever
1) Remove the mounting bolt and lever (10).
8. Oil seal and bearings

1) Remove oil seal (15).
2) Remove 2 bearings (16) from parking
brake case (17).
2) Remove lever (11).
50-310 26 WA320, 320PZ-6

Assembly
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with trans-
fer oil (EO10-CD) before installing.
a Do not reuse the gasket but remove it com-
pletely.
1. Oil seal and bearings

1) Install 2 bearings (16) to parking brake
case (17).
2) Install oil seal (15).
2 Oil seal: Grease (G2-LI)
3. Pin
Install pin (12).
a Install the pin with the grooved part out-
ward.
a Check that dirt is not sticking to the ball
groove and inside of the housing.
2. Oil seal and dust seal

Using tools D3 and D4, press fit oil seal (14)
and dust seal (13).
2 Lips and clearances of oil seal and dust
seal: Silicone grease (ThreeBond
1855 or equivalent)
4. Lever
Install levers (11) and (10).
WA320, 320PZ-6 50-310 27

SEN04202-00 Disassembly and assembly of parking brake assembly
a When installing the levers (11) and (10), a Move cam plate (8) several times so that
match their match marks (a) and (b). balls (9) will be fitted to grooves (c) of cam
2 Mounting bolt: Adhesive (LT-2) plate (8).
3 Mounting bolt: a Check that the cam plate does not hitch
27 34 Nm {2.8 3.5 kgm} on the housing.
5. Balls 7. Plates, discs, and springs

Install 6 balls (9). 1) Install 4 discs (7), 4 wave springs (6), and
a Check that dirt is not sticking to the balls. 5 plates (5).
a Soak the disc in clean transfer oil for
at least 2 minutes before installing
them.
a Check that dirt is not sticking to the
discs and plates.
6. Cam plate
Install cam plate (8).
a Check that dirt is not sticking to the ball
grooves, inside of parking brake housing,
cam plate, discs, and plates.
50-310 28 WA320, 320PZ-6

2) Using tool D27, press plate (5) lightly with 2) Install the O-ring and cover (1).
a press and install 2 spacers (4) and 2 2 O-ring: Grease (G2-LI)
lock bolts (3). 3 Mounting bolt:
a Take care not to press plate (5) too 98 123 Nm {10.0 12.5 kgm}
much and not to damage it.
a Press plate (5) until it is flush with the
parking brake case.
a Move the lever and check that it
returns normally.
2 Lock bolt: Adhesive (LT-2)
3 Lock bolt:
19.6 27.4 Nm {2.0 2.8 kgm}
8. Strainer
1) Install strainer (2).
WA320, 320PZ-6 50-310 29

SEN04202-00

2008 KOMATSU
All Rights Reserved
50-310 30
SEN04203-00
WA320-6
WA320PZ-6
WA320-6 70001 and up


Removal and installation of front axle assembly ............................................................................................. 2
Removal and installation of rear axle assembly.............................................................................................. 4
Disassembly and assembly of axle housing assembly ................................................................................... 7
Disassembly and assembly of differential assembly..................................................................................... 19
WA320, 320PZ-6 50-320 1

SEN04203-00 Removal and installation of front axle assembly
Removal and installation of front 3. Remove work equipment valve upper cover
axle assembly 1
(2).
Removal
k Stop the machine on a level ground and
install the lock bar to the frame to lock the
front and rear frames.
k Release the remaining pressure in the
brake accumulator circuit. For details, see
Testing and adjusting, Releasing remain-
ing pressure in hydraulic circuit.
k Set the support stand to the frame securely.
1. Raise the front part of the chassis with the 4. Disconnect wiring connector F14 (3) and
work equipment and set support stand [1] clamp (10).
under the frame at the rear of the front wheel to
float the front part of the chassis.
5. Disconnect brake hose (4).
2. Lift off front wheel (1). [*1]

a Lift off the front wheel on the other side
similarly.
4 Front wheel (1 side): 340 kg
50-320 2 WA320, 320PZ-6

Removal and installation of front axle assembly SEN04203-00
6. Disconnect front drive shaft (5). [*2] Installation

removal.
[*1]
3 Front wheel mounting bolt:
824 1030 Nm {84 105 kgm}
[*2]
a When installing the drive shaft, check that the
key way of the spider cap is fitted to the key
way of the mating yoke, and then tighten the
mounting bolts.
3 Front drive shaft mounting bolt:
59 74 Nm {6.0 7.5 kgm}
7. Sling front axle assembly (6) temporarily and
support it on jack [2]. Remove the 4 mounting [*3]
bolts on both sides and front axle assembly 3 Front axle mounting bolt:
(6). [*3] 1325 1470 Nm {135 150 kgm}
4 Front axle assembly: 730 kg
q Bleeding air
Bleed air from the brake system. For details,
see Testing and adjusting, Bleeding air from
brake circuit.
WA320, 320PZ-6 50-320 3

SEN04203-00 Removal and installation of rear axle assembly
Removal and installation of rear 4. Lift off rear wheel (1). [*1]
axle assembly 1
a Lift off the rear wheel on the other side
similarly.
Removal 4 Rear wheel (1 side): 340 kg
k Lower the work equipment to the ground
and stop the engine.
k Release the remaining pressure in the
brake accumulator circuit. For details, see
Testing and adjusting, Bleeding air from
brake accumulator circuit.
k Set the support stand to the frame securely.
1. Raise the chassis with the work equipment

(See Removal and installation of front axle
assembly, 1.) and set support stand [1] under
the rear frame in front of the rear wheel. 5. Disconnect brake hose (2) from the axle.
2. Lower the work equipment to the ground hori-

zontally and raise the rear part of the chassis,
and then support the counterweight on support
stand [1] and jack [2].
3. Set support stand [3] between top of each side

of the rear axle and the rear frame and fix the
rear wheel so that it will not lean.
6. Disconnect 2 grease tubes (3).
7. Change the outlet direction of oil pan drain

hose (4).
50-320 4 WA320, 320PZ-6

Removal and installation of rear axle assembly SEN04203-00
8. Remove rear drive shaft (5). [*2] 11. Pull out the rear axle assembly backward to
a Remove coupling (6) to avoid damaging disconnect it from the rear frame assembly.
dust seal (8) in step 11. a When disconnecting the rear axle assem-
bly, take care not to damage dust seal (8)
of rear frame (12).
9. Remove bracket (8) of relay assembly (7). [*3]
12. Lower the crane and jack [3] simultaneously to

remove rear axle assembly (9).
4 Rear axle and support assembly:
780 kg
10. Sling rear axle assembly (9) temporarily, sup-

port it on jack [3], and remove the mounting
bolts (11) of support (10). [*4]
WA320, 320PZ-6 50-320 5

SEN04203-00 Removal and installation of rear axle assembly
Installation
removal.
[*1]
3 Rear wheel mounting bolt:
824 1030 Nm {84 105 kgm}
[*2]
a Check that the radial runout of the rear axle
from the transfer in lateral direction is not
larger than 3 mm. If it is larger than 3 mm,
reduce it by moving the transfer mount.
key way of the spider cap is fitted to the key
mounting bolts.
3 Rear drive shaft mounting bolt:
59 74 Nm {6.0 7.5 kgm}
[*3]
a When removing and installing the mounting
bolts of support (10), take care not to hit the
removed electronic parts with a tool, a bolt, etc.
[*4]
3 Support mounting bolt:
1325 1470 Nm {135 150 kgm}
q Bleeding air
Bleed air from the brake system. For details,
see Testing and adjusting, Bleeding air from
brake circuit.
50-320 6 WA320, 320PZ-6

Disassembly and assembly of axle housing assembly SEN04203-00
Disassembly and assembly of

axle housing assembly 1
Special tools
New/Remodel
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
793T-623-1170 Push tool t 1 Q

1
793T-422-1440 Push tool t 1 Q
793T-422-1410 Seal support t 1 Q
2 793T-422-1420 Seal support t 1 Q
01016-50860 Bolt t 6 2) Sling rear support (30) temporarily and
remove cover (31).
793T-659-1110 Push tool t 1 Q
3
790-201-2750 Spacer t 1
4 793T-422-1430 Holder t 1 Q
790-101-5271 Plate 1
5
790-101-5221 Grip 1
H
01010-51225 Bolt 1
7 790-101-3501 Gear puller q 1
791T-465-1130 Push tool t 1 Q
8
790-201-2670 Plate t 1
9 799-501-1120 Pin t 1
10 790-445-5980 Guide bar t 1
3) Remove thrust plate (32) and rear support
(30).
11 Commercially Dial gauge q 1 4) Remove brake tube and hose assembly
available
(33).
79A-264-0021
12 or commer- Push-pull scale q 1
cially available
Disassembly
a The following photos and illustrations show the
rear axle housing as an example.
1. Draining oil
6 Axle (Each of front and rear axles): 24 l
2. Axle assembly
1) Set the axle assembly on block [1] and
jack [30].
a Set jack [30] so that the axle assem-
bly will not lean when the housing
assembly on one side is removed.
WA320, 320PZ-6 50-320 7

SEN04203-00 Disassembly and assembly of axle housing assembly
3. Axle housing assembly 4. Brakes

1) Sling axle housing assembly (1) tempo- a Remove both brakes according to the fol-
rarily and remove the housing mounting lowing procedure.
bolts and axle housing assembly (1). 1) Remove 2 inside hexagon bolts (34).
a When removing both axle housing
assemblies, make match marks on
the housings and differential case so
that the housing assemblies will not
be mistaken.
2) Remove 2 plates (35), 2 discs (36), and 2

wave springs (37).
2) Set axle housing assembly (1) with the

brake side up.
k When working, take extreme care that
the axle housing assembly will not fall
down.
3) Remove end plate (38).

4) Remove sun gear shaft (39).
50-320 8 WA320, 320PZ-6

5. Planetary carrier assembly 6. Axle shaft

1) Remove axle shaft mounting bolt (2). 1) Sling axle housing assembly (5) about 20
mm.
2) Remove planetary carrier assembly (3).

2) Apply push tool H5 to the end of axle shaft
(6) and hit it with copper hammer [2] to
drive out the shaft.
a The bearing on the planetary carrier
side will be removed.
3) Remove shim (4).

a Record the thickness and quantity of
the shims.
WA320, 320PZ-6 50-320 9

7. Axle shaft bearing 8. Axle housing

a Do not heat the bearing to remove it or cut 1) Remove 3 pins (10) from axle housing
it with gas. (11). (You can pull them out with the
1) When removing bearing (7) from axle hand.)
shaft (6), evenly push in part (a) around 2) Using tool H7, pull up ring gear (9) evenly
the oil seal and sleeve (8) with a screw- to remove it from axle housing (11).
driver toward the flange. a Install tool H8 to the bolt end of tool
2) Make clearance (b) at the contact part of H7 to adjust the height.
bearing (7) and sleeve (8a) to hitch the a Take care that the claws of the puller
claws of the puller. will not come off the ring gear.
3) Install tool H6 securely to clearance (b).
4) Tighten the bolts of tool H6 to remove
bearing (7).
5) Remove oil seal (8).
3) Remove outer races (12) and (13) from

axle housing (11).
50-320 10 WA320, 320PZ-6

9. Planetary carrier 3) Pull roll pin (15) out of removed shaft (16).
1) Using tool H9, drive in roll pin (15) of plan-
etary carrier (14) until it is in the range of
shaft (16).
a Take care not to drive in the roll pin
too deep.
4) Remove pinion gear (17) and 2 bearings

(18) from planetary carrier (14).
5) Similarly, remove the 2nd and 3rd pinion
gears (17) and 2 sets of shaft (16), roll pin
(15), and bearing (18) from planetary car-
rier (14).
6) Remove spacer (19) from planetary carrier
(14).
2) Using tool H10, push out shaft (16) with a

press.
WA320, 320PZ-6 50-320 11

10. Rear axle support (Rear axle only) Assembly

1) Remove thrust washer (50) and retainer 1. Axle housing and axle shaft
(51) from rear axle support (30). 1) Press fit bearing outer races (12) and (13)
to axle housing (11).
2) Remove bushing (52) from rear axle sup-

port (30) and remove packing (53) from 2) Using tool H1, press fit seal (8) and bear-
the retainer side. ing (7) to axle shaft (6) simultaneously.
a Press fit the seal and bearing until oil
seal sleeve (8a) is flush with shaft
end (c), and then check that there is
not clearance between oil seal sleeve
(8a) and bearing (7).
3) Install tool H2 under oil seal (8).

a Adjust tool H2 so that its top will
lightly touch oil seal (8) and the clear-
ance will be even.
50-320 12 WA320, 320PZ-6

2. Axle shaft bearing 3. Selecting shims

1) Erect axle shaft (6) on the block and fix it 1) After bearings (7) and (20) are fitted well,
securely. measure the turning force of hole (d) of
k Perform the work carefully so that the axle housing (11).
axle shaft will not fall. a Carry out this work before installing
2) Sling axle housing (11) vertically, and then the planetary carrier.
lower it slowly. q Turning force (Not static friction, but
a Insert the axle housing by utilizing its dynamic friction)
weight. (Common to front and rear)
2 Fitting part of oil seal and bearing: (Including seal resistance)
Axle oil (AXO80) 25.5 49 N {2.6 5.0 kg}
a After installing the housing, leave tool
H2 installed until step 4). a If the turning force is below the stan-
3) Using tool H3, press fit bearing (20) to dard value, press fit the bearings
axle shaft (6). again and perform the work in step 1).
a Press fit the bearing, turning the axle a If the turning force exceeds the stan-
housing with the hand. dard value, adjust it according to fol-
2 Outside of bearing: lowing steps 2) 4).
Axle oil (AXO80)
4) Remove tool H2 horizontally.
a Check that oil seal (8) does not lean.
a Fit the end face of axle housing (11)
to the flange of oil seal (8) (Reduce
the clearance to below 0.2 mm.)
9JS01378
9JF00886
WA320, 320PZ-6 50-320 13

2) Hold 2 parts of axle shaft and housing

assembly (5) and sling it by 20 30 mm,
as you installed the axle housing.
3) Rotating axle shaft (6), hit the flange with
a copper hammer in the direction of the
arrow several times to drive out axle shaft
(6).
4) Adjust the turning force to the standard
value according to step 1).
9JS01379
1) Put 2 bearings (18) in 1st gear (17) and

install them to planetary carrier (14).
a Using tool H10 and matching pin
holes (f), press fit shaft (16).
2 Shaft: Axle oil (AXO80)
5) Install planetary carrier (14) to the spline

of axle shaft (6) without the gear and place
tool H4.
a Just place tool H4 on planetary carrier
(14). Do not tighten the bolt.
6) Using a depth micrometer, measure dis-
tance (e) from the end of tool H4 to the
end of the axle shaft.
a Subtract thickness (t) of tool H4 from
distance (e), and let the result be (e t).
q Shim thickness = (e t) +0.05
+0
7) After determining the shim thickness,
remove planetary carrier (14).
50-320 14 WA320, 320PZ-6

a Matching the holes of shaft (16) and

roll pin (15), drive roll pin (15) through
push tool H9 so that it will be flush
with planetary carrier (14).
5. Ring gear
Install ring gear (9) to axle housing (11) and
insert 3 pins (10).
a Match the pin holes of the housing and
2) Install spacer (19) in planetary carrier (14). ring gear.
a Insert the spacer from (g) side of
planetary carrier (14) before installing
2nd gear (17).
6. Planetary carrier assembly

1) Install shim (4) selected in steps 3 to the
end of the axle shaft.
3) Similarly to 1), install 2nd and 3rd gears
(17) to planetary carrier (14).
a Using tool H9 and matching pin holes
(f), press fit shaft (16).
a Matching the holes of shaft (16) and
roll pin (15), drive roll pin (15) through
tool H9 so that it will be flush with
planetary carrier (14).
a Hit the end of shaft (16) and the differ-
ential side of gear (17) lightly to push
back the bearing and check that the
gear rotates smoothly.
WA320, 320PZ-6 50-320 15

2) Sling and install planetary carrier assem- 4) Install dial gauge [9] to axle housing (11)
bly (3). and measure the end play of the planetary
k When installing the planetary car- carrier.
rier, take care not to catch your fin- q End play of planetary carrier:
gers in the gear. 0 0.1 mm
a If the end play is out of the standard
range, change the thickness of the
shim in 1) and repeat the above pro-
cedure referring to 3. Selecting
shims.
3) Tighten mounting bolt (2).

a Degrease and clean the bolt hole of
the axle shaft and mounting bolt.
3 Mounting bolt:
490 608 Nm {50 62 kgm} 5) Rotate axle housing (11) 10 or more turns
a Clean the shaft end and planetary to fit it. Then, using push-pull gauge [10],
c ar rier s pline thoroughly before measure the starting effort at the mounting
installing. bolt hole of the axle housing assembly.
q Starting effort
(Common to front and rear)
(Including resistance of seal and
planetary carrier)
25.5 68.6 N {2.6 7.0 kg}
a If the starting effort exceeds the
above range, adjust it again, referring
to 3. Selecting shims above.
50-320 16 WA320, 320PZ-6

7. Brake
1) Install end plate (38).
2) Install sun gear shaft (39).
4) Install 2 inside hexagon bolts (34).
3) Install 2 discs (36), 2 wave springs (37),

and 2 plates (35) in order from the bottom,
observing the following precautions.
a Match the notches of the 2 springs to
each other and set them in the range
marked with A.
The range marked with A is on the
left side of wear gauge (41) in the left
axle (as shown in the photo) and on
the right side of wear gauge (41), or
symmetrically opposite to the photo,
in the right axle.
a When the axle is installed, the 8. Axle housing assembly
notches of the springs, A, and brake 1) Degrease and clean the mating faces of
port must be set as shown in the fol- the axle housing and differential housing
lowing figure. and dry them in air.
a Match the concave lug of lower plate 2) Apply a string of gasket sealant 2 3 mm
(40) to wear gauge (41). in diameter to part (P) of differential hous-
a Match the convex lug of upper plate ing (1).
(35) to wear gauge (41). a Take care that gasket sealant will not
a Wear gauge (41) is seen before project into hollow parts (r) of the
upper plate (35) is set but not seen housing.
after upper plate (35) is set. 2 Mating faces of housings:
Gasket sealant (LOCTITE 515 or
equivalent)
WA320, 320PZ-6 50-320 17

3) Sling axle housing assembly (1) horizon- 2) Sling and install rear axle support (30) and
tally and install it carefully, matching it to install thrust plate (32).
the spline grooves of the sun gear shaft. 2 Periphery of pivot mounting part:
Grease (G2-LI)
3 Mounting bolt:
490 608 Nm {50 62 kgm}
3) Install brake tube and hose assembly (33).
4) Tighten the axle housing mounting bolts in

the diagonal order.
3 Mounting bolt:
245 309 Nm {25.0 31.5 kgm}
4) Install cover (31).
9. Rear axle support 3 Mounting bolt:
1) Fit packing (53) to retainer (51) and install 98 123 Nm {10.0 12.5 kgm}
bushing (52), thrust washer (50), and
retainer (51) to rear axle support (30).
a Clean and dry the inside of the sup-
port to insert the bushing.
a Press fit the bushing with a press
having a surface plate and keep the
support and bushing in parallel.
a Secure clearance of 0.5 mm between
the end of the bushing and the bottom
of the mounting part.
a Set thrust washer (50) with the
groove up (Direct the grove toward
the retainer).
a Direct the lip of the packing toward
the outside of the rear axle support
(toward the axle). q Refilling with oil (Axle housing)
2 Inside of packing: Tighten the drain plug and add oil through the
Grease (G2-LI) (Apply thinly) oil filler to the specified level, and then check
the oil level.
3 Drain plug:
127.4 176.4 Nm {13 18 kgm}
3 Oil filler plug:
93.1 122.5 Nm {9.5 12.5 kgm}
5 Axle oil (AXO80) (Each of front and
rear): 24 l
50-320 18 WA320, 320PZ-6

Disassembly and assembly of differential assembly SEN04203-00
Disassembly and assembly of 2. Removal of long cage assembly (For only

differential assembly 1
front differential)
1) Set the axle assembly on block [1] and
Special tools jack [30].
2) Remove coupling (23).
New/Remodel
a Remove the coupling protector only
Necessity
Sketch
Sym- when it needs to be removed.
Q'ty
Part No. Part name
bol 3) Remove long cage assembly (24).
13 799-301-1500 Oil leak tester t 1

14 797-101-1211 Wrench t 1
15 793-615-1100 Wrench t 1
16 790-201-2840 Push tool t 1
17 797T-423-1320 Push tool t 1 Q
18 792T-413-1130 Push tool t 1 Q
19 793-520-2202 Installer q 3
20 790-190-1500 Pump assembly t 1
21 799-101-5210 Nipple t 1
22 793T-422-1611 Plate t 1 Q
23 791T-465-1210 Push tool t 1 Q
24 790-201-3280 Bolt (14 x 2.0 mm) q 4 3. Disassembly of long cage assembly (For
H
25 790-201-3260 Bolt (12 x 1.75 mm) q 2 only front differential)
26 791-615-2130 Sleeve t 1 1) Remove oil seal (25).
27 791-101-2501 Puller t 1
28 79G-05V-1400 Bar t 1
29 Commercially Depth gauge q 1

available
Commercially
30 available Torque wrench q 1
31 791T-630-2230 Push tool t 1 Q

Commercially
32 available Dial gauge q 1
33 790-201-2830 Spacer t 1
34 791-126-0211 Adapter t 1
Disassembly of front differential

1. Draining oil 2) Using tool H23, push shaft (26) with a
press to remove it from long cage (27).
6 Axle oil (AXO 80) (Each of front and rear
axles): 24 l
a When disassembling the rear differential
q Perform Disassembly and assembly of
axle housing assembly up to 3. 1) to
remove the rear axle support, brake tube,
hose assembly, and right and left axle
housings.
q Perform the procedure in 6. Differential
assembly and after.
a Perform following steps 2 5 when disas-

sembling the front differential.
WA320, 320PZ-6 50-320 19

SEN04203-00 Disassembly and assembly of differential assembly
3) Remove snap ring (28) and ring (29), and 6) Using tool H24, remove front cage assem-
then remove bearing (30) from long cage bly (32).
(27). a Record the thickness and quantity of
the shims.
4. Removal of front cage assembly (Front dif-

ferential) 5. Axle housing
1) Using tool H14, loosen nut (31) before a Referring to Disassembly and assembly of
removing the cage assembly. axle housing assembly, 3. Axle housing
assembly, 1), remove the right and left
axle housings.
6. Differential assembly
1) Place and stabilize differential assembly
on block [1].
a The photo shows the rear differential.
a Remove the right and left rear differ-
entials according to the same proce-
dure.
2) Remove 2 slack adjusters (22).
3) Remove 2 bleeder screws (19).
4) Remove piston (20).
5) Remove coupling (18).
2) Remove cover (10). a Perform this step for only rear differ-
3) Remove the axle oil temperature sensor ential.
(which is hidden by cover (10)) and wiring 6) Remove the mounting bolts of top cover
harness (11) together. (21).
4) Remove brake tube assembly (12).
5) Remove the mounting bolts of front cage
assembly (32).
50-320 20 WA320, 320PZ-6

7) Using tool H25, remove top cover (21). 2) Using tool H26, push out pinion gear
assembly (81) with a press.
8) Remove seal (87) from piston (20).

3) Using bearing puller [31] and tool H26,
push bearing (35) out of pinion gear (36)
with a press.
7. Disassembly of front cage assembly (For

front differential)
1) Remove nut (31) and holder (33).
4) Remove bearing (37), outer races (38)
and (39) from cage (40).
WA320, 320PZ-6 50-320 21

8. Removal of rear cage assembly (For rear 10. Bearing carriers

differential) 1) Sling differential carrier assembly (43)
Remove the mounting bolts. Using tool H24, temporarily.
remove rear cage assembly (42).
a Record the thickness and quantity of the
shims.
2) Remove the mounting bolts and both

bearing carriers (44), using tool H25.
a Make marks on both bearing carriers
9. Disassembly of rear cage assembly (For so that they will not be mistaken.
rear differential) a Record the thickness and quantity of
1) Remove oil seal (82). the shims.
2) For the further disassembly procedure for 3) Remove seal (84) and ring (85) from each
the rear cage assembly, see steps 2) 4) bearing carrier (44).
in 7. Disassembly of front cage assembly a Keep the seal, ring, and shim as a
shown above. set.
50-320 22 WA320, 320PZ-6

4) Using tools H6 and H27, remove bearing 12. Disassembly of standard differential carrier
(86) from each bearing carrier (44). assembly
a When keeping the parts on both sides,
make marks on them so that they will not
be mistaken.
1) Before disconnecting the bevel gear and
case, make match marks on them.
11. Removal of differential carrier assembly

1) Lift off differential carrier assembly (43)
from differential housing (45).
a Take care that the sling will not come
off.
a Do not damage the differential carrier 2) Remove 20 mounting bolts (46) and bevel
assembly by hitting it against the dif- gear (47).
ferential case.
2) Remove the 4 mounting bolts and gear
cover (42).
3) Reverse the case and disconnect cases

(48) and (49).
a Before disconnecting, make match
marks on the cases.
WA320, 320PZ-6 50-320 23

4) Remove washer (51) from case (48). 8) Remove side gear (57) from case (49).
5) Remove side gear (52) from case (49).
9) Remove washer (58) from case (49).

6) Remove pinion gear assembly (53) from
case (49).
10) Using a puller, remove outer race (61)

from case (49).
7) Remove 4 spherical washers (54) and 4 a Remove the outer race of case (48)
pinion gears (55) from spider shaft (56). on the opposite side similarly.
50-320 24 WA320, 320PZ-6

13. Disassembly of limited slip differential 4) Remove washer (66).

assembly (If equipped)
a If the machine is equipped with the limited
slip differential assembly, disassemble it
according to the following procedure.
a When keeping the parts on both sides,
make marks on them so that they will not
be mistaken.
1) Before disconnecting the bevel gear and
case, make match marks on them.
5) Remove 2 plates (67) and 2 discs (68).
2) Remove 20 mounting bolts (46) and bevel

gear (47).
6) Remove pressure ring (69).

a Insert a finger in the hole on the side
of the case to raise the pressure ring.
3) Place the case upside down and remove

cover (63).
a Before disconnecting the cover, make
match marks on it and case.
WA320, 320PZ-6 50-320 25

7) Remove side gear (70). 10) Remove side gear (74).
8) Remove pinion gear assembly (71). 11) Remove pressure ring (75).
9) Remove 4 pinion gears (72) from spider 12) Remove 2 plates (76) and 2 discs (77).
shaft (73).
50-320 26 WA320, 320PZ-6

13) Remove washer (78).
a Removed parts
Assembly
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with axle
oil (AXO80) before installing.
1. Assembly of limited slip differential assem-

bly (if equipped)
1) Install outer race (79) to case (64).
2) Similarly, install outer race (79) to cover
(63).
14) Using tool H28, remove outer race (79)

from inside of case (64). Similarly, using
tool H28, remove the outer race from
inside of cover (63).
3) Install washer (78).
WA320, 320PZ-6 50-320 27

4) Install plate (76), disc (77), plate (76), and 7) Install 4 pinion gears (72) to spider shaft
disc (77) in order from the bottom. (73).
2 Before installing the discs and plates,
soak them in axle oil (AXO80).
8) Install pinion gear assembly (71).
5) Install pressure ring (75).
9) Install side gear (70).
6) Install side gear (74).
50-320 28 WA320, 320PZ-6

10) Install pressure ring (69).
11) Install disc (68), plate (67), disc (68), and

plate (67) in order from the bottom.
2 Before installing the discs and plates,
soak them in axle oil (AXO80).
13) Fit washer (66) to cover (63), and then

install cover (63) temporarily.
a There are grooves on both sides of
the washer.
a Apply axle oil or grease thinly to the
12) Selection of thickness of plate washer so that it will stick to the
i) Using tool H29, measure distance (d) cover.
between the end of case (64) and a When installing the cover, match the
plate (67). ma tch mark s made when it was
a Distance (dd) [(d) 4.8 mm] is removed.
the clearance between the case
and plate.
ii) Select the thickness of the plate so
that distance (dd) [(d) 4.8] will be
0.2 0.6 mm.
a Replace the plates on both sides
so that their thickness (total of 2
pieces) will be the same and
assemble them according to the
procedure in and after 4) shown
above.
q Varieties of plate thickness:
3.0 mm, 3.1 mm
WA320, 320PZ-6 50-320 29

14) Adjust the clearance of the side gear in 15) Install cover (63) to case (64).
the axial direction. 2 Mounting bolt:
i) Measure clearance (e) between the 98 123 Nm {10.0 12.5 kgm}
side gear and washer through the
shaft holes on both sides of the lim-
ited slip differential.
q Clearance (e):
0.15 0.35 mm (on each side)
a If the clearance is out of the stan-
dard range, replace the washer
with new one.
a There are washers 2.0 mm and
2.1 mm thick.
16) Turn over the assembly and install bevel

gear (47).
a When installing the bevel gear, match
the match marks made when it was
removed.
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
a Referring to Disassembly and

assembly of axle housing assembly,
disassemble the brakes of the right
and left axle housings and take out
sun gear shafts (14) which will be
used in the next step.
50-320 30 WA320, 320PZ-6

17) Measure the no-load operation torque. 3) Install washer (58) to case (49) on the
i) Install sun gear shafts (14) to both bevel gear side.
sides of limited slip differential assem- a Install the washer with the dimpled
bly (83). side up (toward the side gear).
ii) Fix the sun gear shaft on one side
and install tool H15 to the sun gear
shaft on the other side.
iii) Install tool H30 to tool H15 and mea-
sure the no-load operation torque.
a When measuring, let the case
rotate freely.
q No-load operation torque:
Max. 10 Nm {Max. 1.0 kgm}
q If the no-load operation torque
exceeds the standard value, dis-
assemble the limited slip differ-
ential again and perform 12)
Selection of thickness of plate
and 14) Adjustment of side gear 4) Install side gear (57) to case (49).
in axial direction.
5) Install 4 pinion gears (55) and 4 spherical

2. Assembly of standard differential carrier washers (54) to spider shaft (56).
assembly
1) Install outer race (61) to case (49) on the
bevel gear side.
2) Similarly, install outer race (61) to the case
(48) on the opposite side.
WA320, 320PZ-6 50-320 31

6) Install pinion gear assembly (53) to case 10) Turn over the assembly and install bevel
(49). gear (47).
a When installing the bevel gear, match
the match marks made when it was
removed.
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
7) Install side gear (52) to case (49).

8) Install washer (51) to case (48).
a Install the washer with the dimpled
side up (toward the side gear).
a Apply axle oil or grease thinly to the
washer so that it will stick to the case.
3. Installation of differential assembly
1) Install gear cover (42).
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
2) Sling differential carrier assembly (43) and
set it to the mounting section of differential
case (45).
a Take care that the sling will not come
off.
a Do not damage the differential carrier
by hitting it against the differential
case.
9) Install case (48) to case (49).

a When installing the case, match the
m atch mar ks mad e when it wa s
removed.
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
50-320 32 WA320, 320PZ-6

a Rotate the bearing several turns to

spread the axle oil to every part of the
bearing.
4) Using tool H12, measure the starting torque
of the bevel gear in the tangential direction.
q Starting torque:
6.9 19.6 N {0.7 2.0 kg}
a If the starting torque is out of the stan-
dard range, adjust it by increasing or
decreasing the shim thickness.
q Varieties of shim thickness:
0.05 mm, 0.2 mm, 0.3 mm, 0.8 mm
a Limit the shim thickness after the adjust-
ment to 0.3 1.25 mm on each side.
4. Bearing carrier
1) Using tool H31 and a press, press fit bear-
ing (86) to bearing carrier (44).
2) Install ring (85) and seal (84) to bearing
carrier (44).
5. Assembly of front cage assembly (For front

differential)
1) Install outer races (39) and (38) to cage
(40).
3) Apply axle oil to the bearing. Using tool

H25, install shims (87) and bearing carri-
ers (44) on both sides.
a Install the shims of the thickness and
quantity checked when disassem-
bled to each bearing carrier.
a Turning the bevel gear, tighten the
mounting bolts.
2 Bearing: Axle oil (AXO80)
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
WA320, 320PZ-6 50-320 33

2) Using tool H16 and a press, press fit bear-

ing (35) to pinion gear (36).
6. Assembly of rear cage assembly (For rear

differential)
3) Erect pinion gear assembly (81) and 1) Referring to 5. Assembly of front cage
install cage assembly (88). assembly, steps 1) 4), assemble the
4) Install bearing (37) to pinion gear assem- rear cage assembly.
bly (81). 2) Apply axle oil to the bearing and rotate the
a Install the bearing by shrink fit at tem- cage several turns to spread the axle oil to
perature below 100C or by using tool every part of the bearing.
H17 and a press. 2 Bearing: Axle oil (AXO80)
3) Install coupling (41).
2 Contact surfaces of coupling and
bearing: Lubricant containing
molybdenum disulfide (LM-G or
LM-P)
3 Mounting bolt:
245 309 Nm {25.0 31.5 kgm}
5) Install holder (33) and nut (31).

a Replace nut (31) with new one.
6) Using tool H14 (See 4. Removal of front
cage assembly), tighten nut (31) to the
specified torque.
a Secure assembly by gripping the out-
side of the pinion gear in a vise.
3 Mounting nut:
441 539 Nm {45 55 kgm}
7) Apply axle oil to the bearing and rotate the
cage several turns to spread the axle oil to
every part of the bearing, and then mea-
sure the following.
2 Bearing: Axle oil (AXO80)
q End play: 0 0.165 mm
q Starting torque at cage mounting hole
(A): 0 60.8 N {0 6.2 kg}
a If the cage is heavy to rotate, replace
the bearing, and then check the start-
ing torque again.
50-320 34 WA320, 320PZ-6

4) Rotate the cage several turns to spread

the axle oil to every part of the bearing,
and then measure the following.
q End play: 0 0.165 mm
q Starting torque at cage mounting hole
(A): 0 60.8 N {0 6.2 kg}
a If the cage is heavy to rotate, replace
the bearing, and then check the start-
ing torque again.
5) Remove coupling (41). Using tool H18,
press fit oil seal (82).
8. Installation of rear cage assembly (For rear

differential)
Install tool H24 to the differential case assem-
bly, and then install shim (90), O-ring, and rear
cage assembly (42).
a For the adjustment of the shims and tight-
ening torque, see 7. Installation of front
cage assembly.

3 Mounting bolt:
245 309 Nm {25.0 31.5 kgm}
7. Installation of front cage assembly (For

front differential)
Install tool H24 to the differential case assem-
bly, and then install shim (89), O-ring, and front
cage assembly (32).
a Install the shims of the thickness and 9. Adjusting backlash
quantity checked when disassembled to Measure the backlash of the bevel gear with
each bearing carrier. tool H32.
a Install the shims with the thinnest one on q Standard backlash: 0.20 0.33 mm
the cage side. a Measure the backlash at 3 places on the
q Adjustment allowance of shims: periphery of the bevel gear and check that
0.74 1.4 mm the dispersion of the measured values is
q Varieties of shim thickness: 0.1 mm or less.
0.05 mm, 0.2 mm, 0.3 mm, 0.6 mm
3 Mounting bolt:
157 196 Nm {16 20 kgm}
WA320, 320PZ-6 50-320 35

1) If the measured backlash is out of the 10. Testing tooth contact

standard range, adjust it by moving a part Apply red lead thinly to the surfaces of the
of the shims to the opposite side. bevel gear teeth and turn the bevel gear in the
a Do not change the total thickness of forward and reverse directions, then check the
the shims on both sides. tooth contact pattern on the bevel gear.
a If the backlash is insufficient, move a a The center of the tooth contact must be as
part of shims (g) to the shims (f). follows.
(Move the bevel gear in the direction q Middle of tooth height
of (A), or to the right in the figure.) q Point on tooth at which distance of (x)
a If the backlash is too large, move a from small end (C) is 24 4 mm
part of shims (f) to the shims (g). a Width (y) of the tooth contact must be 31
(Move the bevel gear in the direction 3 mm.
of (B), or to the left in the figure.) a Check that there is not a strong contact at
tip (A), bottom (B), small end (C), or large
end (D).
9JF01500
11. Adjusting tooth contact

1) If the tooth contact pattern is not proper,
adjust the tooth contact.
a Adjust the tooth contact by increasing
or decreasing the shims on both sides
of the bearing carrier (to move the
bevel gear) and the shims of the cage
assembly (to move the bevel pinion).
a After adjusting the tooth contact,
check the backlash again.
2) If the bevel pinion is too far from the bevel
gear, the tooth contact pattern is as fol-
lows. In this case, adjust the tooth contact
q Decrease the shims of the cage
assembly (on the bevel pinion side) to
move the cage assembly in the direc-
tion of (C).
q Adjust the shims on both sides of the
bearing carrier to move bevel gear in
the direction of (D), far from the bevel
pinion.
a Do not change the total thickness of
the shims on both sides of the bear-
ing carrier.
50-320 36 WA320, 320PZ-6

4) If the bevel gear is too close to the bevel

pinion, the tooth contact pattern is as fol-
q Decrease the shims of the cage
tion of (C).
the direction of (D), far from the bevel
pinion.
3) If the bevel pinion is too close to the bevel ing carrier.
gear, the tooth contact pattern is as fol-
q Increase the shims of the cage
tion of (E).
the direction of (F), close to the bevel
pinion.
ing carrier.
5) If the bevel gear is too far from the bevel
pinion, the tooth contact pattern is as fol-
q Increase the shims of the cage
tion of (E).
the direction of (F), close to the bevel
pinion.
ing carrier.
WA320, 320PZ-6 50-320 37

12. Brake
a Install both brakes according to the same
procedure.
1) Install seal (87) to piston (20).
2 Thinly apply axle oil to the piston
and piston mounting section.
13. Brake oil leakage test

a Action of the piston of the slack adjuster
lowers pressure during the low-pressure
leakage test. To prevent this, use tool
H22.
1) Keep installer [24] (equivalent to tool
2) Using tool H19, press fit piston (20) H19) set.
evenly. k If the brake oil leakage test is per-
a Press fit the piston until it touches the formed without setting installer
housing. [24], the piston will jump out, and
a Do not hit the piston with a plastic that is dangerous.
hammer, etc. to press fit it. (If it is 2) Install tool H22, nipple H21, and pump
press fitted so, it and its O-ring will be H20 to the brake port and bleed all air
damaged.) fr o m t h e b r a k e s y s t e m t h r o u g h t h e
bleeder.
a Tool H22: Fit the O-ring without fail.
3 Tool H22 mounting bolt:
98 123 Nm {10.0 12.5 kgm}
a Bleed air by operating pump H20.
3) Install bleeder screw (19).

4) Install tool H22.
a You may install tool H22 when check-
ing for brake oil leakage.
a Tool H22: Fit the O-ring without fail.
3 Tool H22 mounting bolt:
98 123 Nm {10.0 12.5 kgm}
5) Set installer [24] (equivalent to tool H19).
Using tool H13, supply air into the brake
oil port to fit the piston.
k If the air is supplied without setting
installer [24], the piston will jump
out, and that is dangerous.
50-320 38 WA320, 320PZ-6

3) Perform the low-pressure oil leakage test. 14. Top cover

a Operate tool H20 to raise the pres- 1) Remove bleeder screw (19) temporarily
sure to 98 kPa {1 kg/cm2}. and install top cover (21).
a Leave the system at 98 kPa {1 kg/ 2 Mating face of cover: Adhesive
cm2} for 5 minutes and check that the (LOCTITE 515 or equivalent)
pressure does not lower at all. 3 Mounting bolt:
a If the oil leaks (If the pressure drops 98 123 Nm {10.0 12.5 kgm}
more than the standard), remove the 2) Install slack adjusters (22) to the right and
brake piston and check the seals for left.
damage. a Take care that the O-ring will not
a If the hose is moved while the pres- come off.
sure is measured, the pressure fluctu- 3 Mounting bolt:
ates. Accordingly, do not move the 98 123 Nm {10.0 12.5 kgm}
hose. 3) Install bleeder screw (19).
4) Perform the high-pressure oil leakage
test.
a If oil leakage is not detected by the
low-pressure brake oil leakage test,
operate tool H20 to raise the pressure
to 4,410 kPa {45 kg/cm2}.
a Leave the system at 4,410 kPa {45
kg/cm2} for 5 minutes and check that
the pressure does not drop more than
98 kPa {1 kg/cm2}.
a If the oil leaks (If the pressure drops
more than the standard), remove the
brake piston and check the seals for
damage.
a If the hose is moved while the pres- 15. Axle housing
sure is measured, the pressure fluctu- 1) Referring to Disassembly and assembly of
ates. Accordingly, do not move the axle housing assembly, 8. Axle housing
hose. assembly, install the right and left hous-
5) Remove pump H20, nipple H21, tool H22, ings.
and installer [24] (equivalent to tool H19), 2) For the rear differential, perform step 10.
and then perform the test on the opposite in the Disassembly and assembly of axle
side. housing assembly to install the rear axle
support and the brake tube and hose
assembly.
a Perform steps 16 18 below for only
the front differential.
WA320, 320PZ-6 50-320 39

16. Axle oil temperature sensor (For only front 17. Disassembly of long cage assembly (For
differential) only front differential)
1) Install axle oil temperature sensor and wir- 1) Using tool H33, press fit bearing (30) to
ing harness assembly (11). shaft (26) with a press.
a Install the axle oil temperature sensor a Direct shield side (G) of the bearing
to the back side of cover (10). down.
2 Threads: Gasket sealant (LG-5) 2) Using tool H34, press fit shaft and bearing
3 Axle oil temperature sensor: assembly (91) to long cage (27).
29.4 49 Nm {3 5 kgm}
2) Install cover (10).

3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
3) Install oil temperature sensor clamps (16)

and (17).
3 Mounting bolts (16) and (17):
98 123 Nm {10.0 12.5 kgm}
4) Install brake tube assembly (12).

3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
3) Install ring (29) and snap ring (28).
a Check that part (G) (the shield side of
the bearing) is on the lower side.
4) Using tool H18, press fit oil seal (25).

a Set top (h) of the oil seal rim flush
with end face (i) of the cage.
50-320 40 WA320, 320PZ-6

18. Installation of long cage assembly (For only

front differential)
1) Sling and install long cage assembly (24).
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
2 Contact surfaces of coupling and
bearing: Lubricant containing
molybdenum disulfide (LM-G) or
(LM-P)
3 Mounting bolt:
245 309 Nm {25.0 31.5 kgm}
q Refilling with oil (Axle housing)

Tighten the drain plug and add oil through the
oil filler to the specified level.
3 Drain plug:
127.4 176.4 Nm {13 18 kgm}
3 Oil filler plug:
93.1 122.5 Nm {9.5 12.5 kgm}
5 Axle oil AXO80 (Each of front and rear):
24 l
WA320, 320PZ-6 50-320 41

SEN04203-00

2008 KOMATSU
All Rights Reserved
50-320 42
SEN04204-00
WA320-6
WA320PZ-6
WA320-6 70001 and up


Removal and installation of center hinge pin .................................................................................................. 2
Removal and installation of counterweight assembly ................................................................................... 12
WA320, 320PZ-6 50-400 1

SEN04204-00 Removal and installation of center hinge pin
Removal and installation of center

hinge pin 1
Special tools
New/Remodel
Necessity
Sketch
Q'ty

790-101-5281 Plate 1
1
790-101-5221 Grip 1
Y 01010-51225 Bolt 1
2 793-840-1410 Push tool t 1 3. Remove operator's cab and floor frame
3 793-840-1420 Push tool t 1 assembly (1). For details, see Removal and
4 793-415-1180 Push tool t 1 installation of operator's cab and floor frame
assembly.
Removal
k
4. Remove upper cover (2) of the work equip-
Stop the machine on a level ground and set
ment valve.
rear frames.
k Set supports to the frame securely.
1. Raise the front part of the chassis with the

work equipment and set support stands [1]
under the right and left sides of the frame at
the rear of the front wheels.
5. Disconnect all wiring harness clamps (3)

between the front frame and rear frame from
the rear frame.
2. Set the work equipment horizontally, raise the

counterweight with hydraulic jack [2], and set
support stands [3] under the right and left sides
of the rear frame.

50-400 2 WA320, 320PZ-6

Removal and installation of center hinge pin SEN04204-00
6. Disconnect brake hose (4). [*1] 9. Remove brake hose clamp (8).
10. Disconnect PPC hoses (9) (12) from the work

equipment control valve. [*3]
a Since oil will leak through the disconnected
hoses and tubes, prepare oil receivers.
11. Disconnect port P hose (13) and port T hoses

(14) and (15).
a Plug the disconnected hoses to prevent oil
leakage.
7. Disconnect front drive shaft (5). [*2]
8. Remove 2 hose clamp brackets (6) and (7).
Reference: The photo shows the work equip-

ment valve seen from the rear lower direction.
WA320, 320PZ-6 50-400 3

12. Remove pins (11) and hoses (12) and (13) 2) Remove the mounting bolt, cover (15) and
from the bottom side of both steering cylinders shim (17).
to disconnect these cylinders. [*4] a Record the thickness and quantity of
a Record the thickness and quantity of the the shims.
shims.
3) Adjust the height of the front frame and

13. Remove the lower hinge pin. [*5] rear frame with the hydraulic jack so that
1) Remove lock bolt (14a). you can pull out the pin easily, and then
2) Remove lower hinge pin (14b). remove upper hinge pin (16). [*7]
4) Remove upper spacer (18).
14. Remove the upper hinge pin. [*6]

1) Remove mounting bolt (14c). 15. Disconnect the front frame and rear frame. [*8]
a Record the thickness and quantity of 1) Set hand lift truck [4] under bucket (19).
the shims.
AJF00736
50-400 4 WA320, 320PZ-6

2) Using a bar, etc., raise front frame assem- 2) Remove retainer (24) and shims (25).
bly (20) by 2 3 mm to move lower spacer a Record the thickness and quantity of
(21) of the upper hinge from rear frame the shims.
assembly (22). 3) Remove dust seal (26) from retainer (24).
a You may raise the front frame assem-
bly by 2 3 mm with a large-sized
crane, if available.
AJF00740
9JF00909
4) Remove bearing (27a) and spacer (27b)

with push tool Y1.
3) Turn the tires to move front frame assem-

bly (20) forward.
AJF00737
17. Disassemble the upper hinge of the front

frame. [*10]
1) Remove lower spacer (28).
16. Disassemble the lower hinge of the front 2) Remove dust seal (29).
frame. [*9] 3) Remove retainer (30) and shim (31).
1) Remove dust seal (23). a Record the thickness and quantity of
the shims.
4) Remove dust seal (32) from retainer (30).
AJF00739
WA320, 320PZ-6 50-400 5

5) Remove bearing (33a) and spacer (33b) Installation

with push tool Y2. q Carry out installation in the reverse order to
removal.
[*1]
a Bleed air from the brake. For details, see Test-
ing and adjusting, Bleeding air from wheel
brake circuit.
[*2]
3 Front drive shaft mounting bolt:
59 74 Nm {6.0 7.5 kgm}
key way of the spider cap is fitted in the key
mounting bolts.
18. Remove 2 bushings (34) from the lower hinge
of the rear frame. [*11] [*3]
a Connect PPC hoses (9) (12) according to
their band colors shown below.
q Work equipment lever specification: 2 levers
No. Connecting point Band color
(9) Bucket DUMP Blue
AJF00743 (10) Bucket TILT Red
(11) Lift arm LOWER Orange
(12) Lift arm RAISE Yellow
[*4]
a Adjust the shim so that the total of the upper
and lower clearances between the frame and
cylinder will be less than 0.5 mm.
0.5 mm, 1 mm
2 Inside of bushing on cylinder side and
dust seal:
Lubricant containing molybdenum
disulfide (LM-P)
50-400 6 WA320, 320PZ-6

[*5] [*6] [*7] [*8] 4. Insert upper hinge pin (16) and lower hinge pin
a Install the upper hinge pin and lower hinge pin (14b) to the end.
5. Install upper spacer (18).
1. Set hand lift truck [4] under the bucket and turn a Install the spacer with the chamfered part
the tires to move the front frame assembly (20) on the bearing side.
toward the rear frame. 2 Upper spacer:
Lubricant containing molybdenum
disulfide (LM-P)
2. Using a bar, etc., raise front frame assembly

(20) by 2 3 mm to move spacer (21) to the
spacer of rear frame assembly (22). 6. Tighten cover (15) of upper hinge pin (16) with
a You may raise the front frame assembly 3 bolts of the centre.
by 2 3 mm with a large-sized crane, if a Do not insert the shim for the upper hinge
available. pin.
2 Mounting bolt:
Adhesive: (Loctite #2701)
3 Mounting bolt:
186 226 Nm {19 23 kgm}
7. Measure clearance between the bottom of

9JF00909 cover (15) and rear frame top with a clearance
gauge, and then select shims so that the maxi-
mum clearance will be less than 0.2 mm when
shim (17) are inserted.
q Standard shim thickness: 1 mm
0.1 mm, 0.5 mm
3. Align the upper and lower pin holes.

a Using a hydraulic jack, adjust the height of
the front and rear frames and align the pin
holes.
k When aligning the pin holes, use a bar.
Never insert your fingers in the pin
holes.
WA320, 320PZ-6 50-400 7

8. Insert selected shim (17) between cover (15) [*9] [*10] [*11]
and rear frame and tighten the 6 mounting a Assemble the upper hinge and lower hinge
bolts. according to the following procedure.
2 Mounting bolt: 1. Install 2 bushings (34) to the lower hinge of the
Adhesive: (Loctite #2701) rear frame.
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
9. Install lock bolt (14a) of lower hinge pin (14b).
AJF00743
2. Assemble the upper hinge of the front frame.

1) Using push tool Y3, press fit bearing (33a)
and spacer (33b) to the front frame.
a Since the clearance of bearing (33a)
a A clearance of 1 mm should be made at and spacer (33b) is adjusted properly,
(b) between bushing (35) and lower hinge do not change their combination.
pin (14b). a Since bearing (33a) and spacer (33b)
are an assembly, always replace
them as a set.
a Press fit bearing (33a) and spacer
(33b) securely so that there is no
clearance between the bearing and
frame.
2 Bearing: Grease (G2-LI)
9JF00917
10. Install mounting bolt (14c) of upper hinge pin

(16).
50-400 8 WA320, 320PZ-6

2) Press fit dust seal (29) to the front frame. 5) Tighten the 3 mounting bolts of retainer
a Press fit the dust seal with the lip out. (30) evenly.
2 Lip of dust seal: Grease (G2-LI) 3 Retainer mounting bolt:
3) Install lower spacer (28). 19.6 10% Nm {2 10% kgm}
a Install the spacer with the chamfered 6) Measure clearance (a) between retainer
part on the bearing side. (30) and front frame with a clearance
2 Lower spacer: gauge, and then select shims so that the
Lubricant containing molybde- maximum clearance will be less than 0.1
num disulfide (LM-P) mm when the shims are inserted.
0.1 mm, 0.5 mm, 1.0 mm
AJF00741
4) Press fit dust seal (32) to retainer (30).

a Press fit the dust seal with the lip out.
2 Lip of dust seal: Grease (G2-LI)
7) Insert selected shim (31) and tighten
retainer (30) with the 6 mounting bolts.
2 Mounting bolt:
Adhesive: (Loctite #2701)
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
9JF00913
WA320, 320PZ-6 50-400 9

3. Assemble the lower hinge of the front frame. 3) Press fit dust seal (26) to retainer (24).
1) Using push tool Y4, press fit bearing (27a) a Press fit the dust seal with the lip out.
and spacer (27b) to the front frame. 2 Lip of dust seal: Grease (G2-LI)
a Since the clearance of bearing (27a)
and spacer (27b) is adjusted properly,
do not change their combination.
a Since bearing (27a) and spacer (27b)
are an assembly, always replace
them as a set.
a Press fit bearing (27a) and spacer
(27b) securely so that there is no
clearance between the bearing and
frame.
2 Bearing: Grease (G2-LI)
4) Tighten the 3 mounting bolts of retainer

(24) evenly.
3 Retainer mounting bolt:
19.6 10% Nm {2 10% kgm}
5) Measure the clearance between retainer
(24) and front frame with clearance gauge
[6], and then select shims so that the max-
imum clearance will be less than 0.1 mm
when the shims are inserted.
2) Press fit dust seal (23) to the front frame. 0.1 mm, 0.5 mm
a Press fit the dust seal with the lip out.
2 Lip of dust seal: Grease (G2-LI)
AJF00739
50-400 10 WA320, 320PZ-6

6) Insert selected shim (25) and tighten the 9 q Refilling with oil (Hydraulic tank)
mounting bolts. Add oil through the oil filler to the specified
2 Mounting bolt: level. Run the engine to circulate the oil
Adhensive: (Loctite #2701) through the system. Then, check the oil level
3 Mounting bolt: again.
5
98 123 Nm {10.0 12.5 kgm}
Hydraulic oil (For details, see Table of
fuel, coolant and lubricants):
Only necessary quantity
AJF00747
WA320, 320PZ-6 50-400 11

SEN04204-00 Removal and installation of counterweight assembly
Removal and installation of 5. Open the radiator grille and sling it temporarily.
counterweight assembly 1
6. Open the engine left side cover and disconnect
Removal wiring connector CN-BR1 (8).
rear frames.
1. Disconnect battery negative () terminal (1)

from the right side, and then disconnect battery
terminal (2).
2. Disconnect wiring harness connectors CN-R23

(3) and CN-R24 (4).
7. Disconnect both damper gas cylinders (9).
3. Disconnect battery terminals (5) and (6) from

the left side.
8. Remove the 4 mounting bolts and lift off the
4. Disconnect wiring harness connector CN-R22 radiator grille (10).
4
(7).
Radiator grille: 25 kg
50-400 12 WA320, 320PZ-6

Removal and installation of counterweight assembly SEN04204-00
9. Sling counterweight (11) temporarily and Installation

remove the mounting bolt, and then remove q Carry out installation in the reverse order to
counterweight (11). [*1] removal.
4 Counterweight and batteries (both)
[*1]
3
assembly: 2,100 kg
Mounting bolt:
824 1,030 Nm {84 105 kgm}
WA320, 320PZ-6 50-400 13

SEN04204-00

2008 KOMATSU
All Rights Reserved
50-400 14
SEN04205-00
WA320-6
WA320PZ-6
WA320-6 70001 and up


Removal and installation of HST pump and 4-gear pump assembly .............................................................. 2
Disassembly and assembly of HST pump assembly ...................................................................................... 5
Removal and installation of HST motor 1 assembly ..................................................................................... 32
Removal and installation of HST motor 2 assembly ..................................................................................... 34
Disassembly and assembly of HST motor assembly.................................................................................... 36
Removal and installation of work equipment control valve assembly ........................................................... 52
Removal and installation of hydraulic tank assembly.................................................................................... 54
Disassembly and assembly of hydraulic cylinder assembly ......................................................................... 56
WA320, 320PZ-6 50-500 1

SEN04205-00 Removal and installation of HST pump and 4-gear pump assembly
Removal and installation of HST 4. Disconnect the following tubes and hoses.
pump and 4-gear pump assembly 1 q (1): 4 HST pump discharge hoses
q (2): Hose between charge valve port (A)
Removal and fan motor (IN) hose
rear frames.
k Slowly loosen the oil filler cap of the
hydraulic tank to release the residual pres-
sure in the hydraulic tank.

leakage.
a Put tags to the disconnected hoses and pipes q (3): Hose between charge valve port (P)
and record the installed positions etc. on them. and brake/fan pump
q (4): 2 HST filter hoses
q Precautions for handling refrigerant
k Collect refrigerant (R134a) beforehand.
the atmosphere.
k If the refrigerant (R134a) gets inside
Therefore, make sure to wear protec-
tive glasses when collecting or filling
work must be conducted by a qualified
person.
q (5): Steering pump suction tube
q (6): HST pump port (G) hose
q (7): HST pump port (S) hose
q (8): Parking brake solenoid port (T) hose
1. Recover the refrigerant (R134a).
2. Drain the hydraulic oil.

6 Hydraulic tank: 89 l
3. Remove the operator's cab assembly. For

details, see Removal and installation of opera-
tor's cab and floor frame assembly. [*1]
50-500 2 WA320, 320PZ-6

Removal and installation of HST pump and 4-gear pump assembly SEN04205-00
q (9), (10): HST pump port (PS) hose 6. Sling HST pump and 4-gear pump assembly
q (11), (12): HST pump port (YS) hose (22) temporarily, and then remove its 5 mount-
q (13): HST pump port (G) hose ing bolts and it. [*2]
4 HST pump and 4-gear pump assembly:
150 kg
q (14): HST motor M1 port (T2) hose

q (15): HST motor M2 port (T2) hose
q (16): Steering priority valve port (P) hose
q (17): Hose between work equipment
pump and cut-off valve port (P)
q (18): Transfer clutch valve port (T) hose
q (19): Transfer lubrication hose
q (20): Transfer cooler inlet hose
5. Disconnect wiring connector (T05) (21).
WA320, 320PZ-6 50-500 3

SEN04205-00 Removal and installation of HST pump and 4-gear pump assembly
Installation
removal.
[*1]
a When installing the hoses of the air conditioner
circuit, take care that dirt, dust, water, etc. will
not enter them.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8 or ZEXEL ZXL100PG
(equivalent to PAG46)) to O-ring (70). 1. If boss (23) was removed from the HST pump
3 Threaded part of hose (M16 1.5): assembly, install it according to the following
12 15 Nm {1.2 1.5 kgm} procedure.
3 Threaded part of hose (M22 1.5): a Install boss (23) so that it will be flush with
20 25 Nm {2.0 2.5 kgm} the shaft end of pump (24).
3 Threaded part of hose (M24 1.5): q Level difference between boss and pump
30 35 Nm {3.0 3.5 kgm} shaft end: Max. 0.5 mm
q Charging with refrigerant (R134a) 2. Tighten mounting bolt (25) of boss (23).
Charge the air conditioner circuit with refriger- 3 Mounting bolt: 210 Nm {21.4 kgm}
ant (R134a).
[*2]
2 Mating face of pump:
Gasket sealant (LG-6)
3 Mounting bolt:
A: 245 309 Nm {25.0 31.5 kgm}
B: 98 123 Nm {10.0 12.5 kgm}

again.
50-500 4 WA320, 320PZ-6

Disassembly and assembly of HST pump assembly SEN04205-00
Disassembly and assembly of 2. Low pressure valve assembly

HST pump assembly 1
1) Remove low pressure valve assembly (2).
a Do not change adjustment screw.
Special tools
New/Remodel
Necessity
Sketch
Sym-
Q'ty
Part No. Part Name
bol
1 790-201-2720 Push tool q 1

790-201-2730 Push tool t 1
S 2
790-201-2830 Push tool t 1
3 790-201-2740 Push tool q 1
Disassembly
a If the pump body is disassembled, the assem- 2) Disassemble the low pressure relief valve
bly special tool will be required. See Assembly according to the following procedure, if
3. 5). necessary.
a General view a Before loosening the adjustment
screw, check the adjustment dimen-
sion.
i) Remove spring (3) and spring seat
(4).
ii) Remove piston (5).
iii) Remove locknut (6).
iv) Remove adjustment screw (7) from
holder (8).
1. High pressure relief valve assembly

1) Remove 2 high pressure relief valve
assemblies (1).
a Do not change adjustment screw.
a Control: O-ring, housing.
a Do not disassemble the high pressure
relief valve assemblies, except the O- CJW11904
rings and backup rings.
WA320, 320PZ-6 50-500 5

SEN04205-00 Disassembly and assembly of HST pump assembly
3. High pressure cut-off valve assembly

1) Remove high pressure cut-off valve
assembly (9)
a Unscrew setting cartridge completely.
a Control: O-ring, housing.
CJW11906
2) Disassemble the high pressure cut-off

valve according to the following proce-
dure, if necessary.
a Before loosening the adjustment
screw, check the adjustment dimen-
sion.
i) Remove spring seat (10) and spring
(11) from the pump case.
ii) Remove barrel assembly (12) from 4. Speed-related valve (DA valve) assembly
the pump case. 1) Remove speed-related valve assembly
iii) Remove spring seat (13) and shuttle (19).
spool (15) from barrel (12).
iv) Remove spool (16) and piston (17)
from barrel (12).
v) Screw a bolt of M3 x 140 or longer
one and pull valve seat (14) out of the
pump case.
vi) Remove locknut (18), and then
remove adjustment screw (97) from
holder (98).
50-500 6 WA320, 320PZ-6

5. Directional solenoid valve (34) 3) Disassemble the valve housing assembly

1) Remove directional solenoid valve assem- (35) according to the following procedure.
bly (34). i) Remove 2 springs (37) and 2 collars
(38).
ii) Remove piston (39).
a Do not remove 4 plugs (41) and plug
(42) from housing.
CJW12132
2) Remove 2 solenoid valves (36) from direc-

tional solenoid valve assembly (34).
a Remove cap (36B) by turning it and
remove coil (36A) by pulling it from
the solenoid valve, and then remove
the tube from the valve housing
assembly (35).
WA320, 320PZ-6 50-500 7

6. Charge pump assembly (44) 7. Port plate assembly (51)

1) Remove 4 mounting bolts (97) and charge 1) Mark the position (angle) of the indexing
pump assembly (44). screw (50), m0.
2) Remove wear plate (43). a Record setting measure (angle).
3) Remove gear (46). 2) Set the indexing screw to disassembly
4) Remove coupling (48) and key (49). position (a).(0.)
a Do not remove bearing metal (47) from
flange (45).
CJW12131
3) Mark position of the port plate, m1.

4) Loosen port plate fixation.
5) Lift off port plate assembly (51) and con-

trol plate (52).
50-500 8 WA320, 320PZ-6

8. Cylinder block and piston assembly (54)

1) Press cylinder (53) to the bottom.
2) Remove fixing indexing screw (50).
3) Remove cylinder block and piston assem-

bly (54).
WA320, 320PZ-6 50-500 9

4) Disassemble cylinder block and piston

assembly (54) according to the following
procedure.
i) Remove the assembly of pistons (57)

and retainer (58) from cylinder block
(56).
ii) Remove 9 pistons (57) from retainer
(58).
50-500 10 WA320, 320PZ-6

iii)Remove retainer guide (59) from cyl- a Check of pistons

inder block (56). q Check that there are no scratches or
iv) Remove shim (60) and spring (61). metal deposits on sliding surface (b),
and there is no axial play (c), (other-
wise: pistons must be replaced in
sets).
CJW12142
a Check of cylinder block and control plate.

q Cylinder bores (d), splines (e).
a When any of cylinder block (56), control

plate (52), retainer guide (59), retainer
(58), and shim (60) needs to be replaced,
replace the whole cylinder block since a
dimension of shim (60) must be adjusted.
v) Remove snap ring (63) from the cylin-
der block. q Cylinder surface ( f ) free of scoring.
k Snap ring (63) will jump out. Take q Control plate (g) without scoring.
care. a Fit faces (f) and (g) (having notch (B) on
vi) Remove spring (62) and 2 shims (65). the ellipse) together.
WA320, 320PZ-6 50-500 11

9. Seal 10. Drive shaft assembly

1) Protect drive shaft (66). 1) Remove drive shaft assembly (66) with
2) Remove snap ring (67). plastic hammer strokes.
3) Screw [1] in sheet metal screw into the 2) Disassemble the drive shaft assembly
holes fitted with rubber. according to the following procedure.
4) Pull out shaft seal (68) with pliers. i) Remove snap ring (70).
ii) Remove bearing (71) from drive shaft
(72).
a Check of drive shaft
q Splines for damage or fretting
q Running surfaces
q Groove cut by shaft seal
5) Remove snap ring (69).
50-500 12 WA320, 320PZ-6

11. Swivel cradle (73), bearing cups (74) q Bearing surfaces ( j ) of cradle (76)
1) Remove swivel cradle (73).
2) Remove bearing cups (74).
a Check
q Bearing cups set.
4) Remove lever (75) from cradle (73).

a Check of cradle lever (75)
3) Remove wire (95), articulate pin (96) and

bearing (74b) from swivel cradle (73).
12. Servo cylinder assembly

1) Remove plugs (77).
2) Remove joint pins (78).
a Check of cradle (76)

q Sliding surface (h) free from scoring
WA320, 320PZ-6 50-500 13

3) Mark position m2, m3 of covers (80), (81), 7) Remove servo piston assembly (82).
note measure of zero position ( k ) .
4) Loosen nut (79).
a Check of groove (A)
5) Remove covers (80) and (81). 8) Disassemble servo piston assembly (82)
a Disassemble one side first, then dis-
assemble the other side.
i) Using tool S1, push collar (83).
ii) Break and remove plastic cap (86).
(Prepare new one for assembly.)
iii) Remove ring (84).
iv) Remove snap ring (85).
6) Remove O-rings (101) from both sides.
v) Remove collar (83).

vi) Remove large spring (87) and small
spring (88).
vii) Remove collar (89).
50-500 14 WA320, 320PZ-6

viii) Disassemble the opposite side simi- Assembly

larly. a Clean all the parts and remove burrs, etc.
ix) Remove rod (91) from piston (90). a Coat the rotary parts and sliding parts with
engine oil (EO10-CD) before installing.
a If the tightening torque of a mounting bolt, nut,
or plug is not shown in this manual, see the
tightening torque table.
1. Pump case
1) Install guide ring (92).
a When any of rod (91), collar (83),

snap ring (85), piston (90), and ring
(84) needs to be replaced, replace all
of the servo piston assembly (82)
since a dimension of ring (84) must
be adjusted.
2) Install O-ring (94).
13. Pump case
1) Remove guide ring (92) from the servo
cylinder mounting part (100) of pump
case.
2) Remove seal ring (93) and O-ring (94).
3) Install seal ring (93) over O-ring (94).
WA320, 320PZ-6 50-500 15

a The deformation of the seal has v) Using tool S1, push collar (83).
to be done with care so as not to vi) Install snap ring (85).
damage the sealing edges. vii) Install ring (84).
a Check the position of seal ring viii) Install new plastic cap (86).
(93). If necessary, straighten it ix) Turn over.
using a finger. x) Assemble the opposite side similarly.
2. Servo piston assembly (82)

a Assemble the servo piston assembly in an
oil pan.
1) Dip piston (90), rod (91), springs (87) and
(88), collars (83) and (89) in engine oil
(EO10-CD).
2) Assemble the servo piston assembly
i) Install rod (91) to piston (90).
3) Insert guide thorn [4] into the servo piston

assembly (82).
4) Grease slightly guide thorn [4].
5) Install servo piston assembly (82) with
guide thorn [4].
a Assemble either side first, then assemble

the other side.
ii) Install collar (89).
iii) Install small spring (88) and large
spring (87).
iv) Install collar (83).
a When any of rod (91), collar (83),

snap ring (85), piston (90), and ring
(84) needs to be replaced, replace all
of the servo piston assembly (82)
since a dimension of ring (84) must
be adjusted.
50-500 16 WA320, 320PZ-6

3. Cradle and bearing cups 3) Insert completely swivel cradle (73) into
1) Insert bearing cup set (74a). housing.
a Fit hole (c) of cup set (74a) to the pin a Assistance: Devices, e.g. clamp, rub-
in the case. ber rings, grease and string
a Pay attention for correct seat of
swivel cradle (73) in the housing.
2) Swivel cradle (73)

Assemble bearing (74b), wire (95), lever
(75) and articulating pin (96) to cradle a Sliding stone guidance in piston (82).
(76).
k Remove auxiliary device.

a Completed cradle holding device
WA320, 320PZ-6 50-500 17

a Check: Location of the swivel bearing

in the bearing
q Centralize swivel (73) by using a
measuring device (dial gauge or
depth measurement [5])
q Check points 1 and 2 they should
have the same dimension. CJW11961
CJW11958
6) Hold swash plate in position utilizing the

seat screw.
k Do not use force.
4) Fit joint pin (78) and plug (77).

a Pinch wire (95) in pin (78).
CJW11960
5) Make holding devices [6] (2 pieces).

a Holding device [6] swivel cradle
50-500 18 WA320, 320PZ-6

7) Install second holding device [6] diago- a Before setting seal (68), perform the fol-
nally and fix the swash plate. lowing procedures.
6) Measure depth (d1) to the groove bottom
4. Drive shaft assembly of snap ring (67).
a Install the bearing to the shaft in the cor- 7) Make a mark of the insertion depth of
rect direction. push tool S3 (finishing position) (m4 = d1)
1) Install the ring to the shaft first, and then on push tool S3.
install the bearing to the shaft. 8) Using tool S3, press fit seal (68).
2) Using tool S2, press fit bearing (71) to a Threads of shaft: 5/8-11UNC-2B,
drive shaft (72). Thread depth: 36 mm
3) Install snap ring (70). 9) Install snap ring (67).
4) Install drive shaft assembly (66).

5) Install snap ring (69).
WA320, 320PZ-6 50-500 19

5. Cylinder block and piston assembly

1) Assemble the cylinder block and piston
assembly according to the following pro-
cedure.
CJW11921
50-500 20 WA320, 320PZ-6

i) Install 2 shims (65) and spring (62) to 2) Remove holding device [6].
the cylinder block. a Fit cylinder completely with pistons
ii) Compress spring (62) and install snap and retaining device.
ring (63).
iii) Install spring (61) and shim (60) to
cylinder block (56).
a When any of cylinder block (56), con-
trol plate (52), retainer guide (59),
retainer (58), and shim (60) needs to
be replaced, replace the whole cylin-
der block since a dimension of shim
(60) must be adjusted.
iv) Install retainer guide (59).
3) Assembly aid:
Hold the cylinder block and piston assem-
CJW12142 bly (54) by using an O-ring (96).
6. Control plate (52)

a Control plate clockwise rotation - indexed
in the direction of rotation.
a Noise grooves are machined - in based on
direction of rotation.
a Notch (B) is seen on 1 side.
v) Install 9 pistons (57) to retainer (58).
vi) Install piston and retainer assembly to
cylinder block (56).
a Oil piston and piston pad.
WA320, 320PZ-6 50-500 21

a Indexing screw basic setting - indexing

screw (50) (The end is eccentric.)
Dimension (m): 20 0.75 mm
7. Port plate (51)

1) Assemble port plate (51), matching (m1).
k Spring preloaded!
1) Press cylinder block (56) to the bottom. 2) Insert port plate assembly (51) into hous-
2) Screw in indexing screw (50). ing, guided with 2 guide bolts [1] that
a Groove in mounting position. screwed opposite angle.
(The groove is directed up in the fol-
lowing figure.)
3) Locking screw (50) - Observe adjusting

measure, the angle (m0).
3) Insert control plate (52) - clockwise rota-
tion.
a Insert the control plate so that notch (B)
will not be seen.
50-500 22 WA320, 320PZ-6

8. Servo piston cover 10. Directional solenoid valve (34)

1) Install servo piston covers (80) and (81) to 1) Assemble valve housing assembly (35)
both sides of match mark position (m2), according to the following procedure.
(m3). i) Install plug (42) to housing.
a Cover (80) will be removed because 2 Threads of plug:
of filling oil. ThreeBond No. 1305 or equivalent
ii) Install 4 plugs (41).
3 Plug: 5.6 Nm {0.57 kgm}
iii) Install piston (39).
iv) Install 2 collars (38) and 2 springs
(37).
CJW12132
9. Charge pump assembly (44)

1) Install wear plate (43)
2) Install coupling (48) and key (49).
a Bearing metal (47) is already in flange
(45).
3) Install gear (46) to flange (45).
4) Install charge pump assembly (44) with 4
mounting bolts (97).
CJW12131
2) Install 2 solenoid valves (36) to valve

housing assembly (35).
a Fit the tube to the solenoid valve
housing and install coil (36A) and cap
(36B).
WA320, 320PZ-6 50-500 23

3) Install directional solenoid valve assembly

(34).
3 Mounting bolt: 10.4 Nm {1 kgm}
CJW11906
11. Speed-related valve (DA valve)

1) Fit the O-ring and install speed-related
valve assembly (19).
2) Fit the O-ring and install high pressure cut-

off valve assembly (9).
a After installing the pump assembly to
the machine, adjust the high pressure
cut-off valve assembly. For details,
see Testing and adjusting, Testing
and adjusting HST oil pressure.
12. High pressure cut-off valve assembly
1) Assemble the high pressure cut-off valve
assembly according to the following pro-
cedure.
i) Install adjustment screw (97) and
locknut (18) to holder (98).
ii) Install piston (17) and spool (16) to
barrel (12).
iii) Install shuttle spool (15), valve seat
(14), and spring seat (13) to barrel
(12).
iv) Install barrel assembly (12) to the
pump case.
v) Install spring (11) and spring seat (10)
to the pump case.
a Set the spring to the dimension mea-
sured before disassembly.
50-500 24 WA320, 320PZ-6

13. Low pressure relief valve assembly 14. High pressure relief valve assembly
1) Assemble the low pressure relief valve Fit the O-ring and install 2 high pressure relief
assembly according to the following pro- valve assemblies (1).
cedure. 3 High pressure relief valve assembly:
i) Install adjustment screw (7) to holder 200 10 Nm {20.39 1.02 kgm}
(8).
ii) Install locknut (6).
iii) Install piston (5).
iv) Install spring seat (4) and spring (3) to
the pump case.
CJW11904
15. Filling with oil

a Remove servo piston cover (80).
(See next item.)
Fill up hydraulic aggregates with medium
before start-up.
2) Fit the O-ring and install low pressure

relief valve assembly (2).
3 Low pressure relief valve assem-
bly: 70 Nm {7.14 kgm}
WA320, 320PZ-6 50-500 25

16. Servo piston cover (80) 17. Before starting

1) Install servo piston cover (80) to match q Observe the operating instructions before
mark position (m3). starting.
2) Adjust zero position according to mea- q Check the machine for remarkable faults.
sure, (k). q Do not operate the machine with defective
k Adjustments of the correct zero posi- instruments, warning lights or control ele-
tion should be carried out after installa- ments.
tion of the machine or on the bench q All safety devices must be in a secure
test. position.
q Do not carry with you movable objects or
secure them to the machine.
q Keep oily and inflammable material away
from the machine.
q Before entering the operators cab, check
if persons or obstacles are beside or
beneath the machine.
q Be careful when entering the operators
cab, use stairs and handles.
q Adjust your seat before starting.
50-500 26 WA320, 320PZ-6

18. Tightening torque table

a If the tightening torque of a mounting bolt,
nut, or plug is not shown in this manual,
tighten that part according to the following
1) Bolts
The values stated are valid for bolts with
metric ISO threads to DIN 13 part 13, as
well as head areas to DIN 912 socked
head cap screws, DIN 913 hexagon bolt
or DIN 933 hexagon bolts with threads up
to the head.
Tensile strength class
Thread 8.8 10.9 12.9
Nm kgm Nm kgm Nm kgm
M3 1.1 0.11 1.6 0.16 1.9 0.19
M4 3.1 0.32 4.5 0.46 5.3 0.54
M5 6.1 0.62 8.9 0.91 10.4 1.06
M6 10.4 1.06 15.5 1.58 18 1.84
M8 25 2.55 37 3.77 43 4.38
M10 51 5.20 75 7.65 87 8.87
M12 87 8.87 130 13.26 150 15.30
M14 140 14.28 205 20.90 240 24.47
M16 215 21.92 310 31.61 370 37.73
M18 300 30.59 430 43.85 510 52.01
M20 430 43.85 620 63.22 720 73.42
M22 580 59.14 830 84.64 970 98.91
M24 740 75.46 1060 108.09 1240 126.44
WA320, 320PZ-6 50-500 27

(1) Plugs
i) Plugs with internal hexagon and pro-
file seal ring
Tightening torque Tightening torque

Thread Thread
Nm kgm Nm kgm
M8 x 1 5 0.51 G 1/8 A 10 1.02
M10 x 1 10 1.02 G 1/4 A 30 3.06
M12 x 1.5 20 2.04 G 3/8 A 35 3.57
M14 x 1.5 30 3.06 G 1/2 A 60 6.12
M16 x 1.5 35 3.57 G 3/4 A 90 9.18
M18 x 1.5 40 4.08 G1A 140 14.28
M20 x 1.5 50 5.10 G 11/4 A 240 24.47
M22 x 1.5 60 6.12 G 11/2 A 300 30.59
M26 x 1.5 70 7.14
M27 x 2 90 9.18
M30 x 1.5 100 10.20
M33 x 2 140 14.28
M42 x 2 240 24.47
M48 x 2 300 30.59
50-500 28 WA320, 320PZ-6

ii) Plugs with internal hexagon, O-ring

and UNF-, UN- threads to SAE J 514
Tightening torque Tightening torque

Thread Thread
Nm kgm Nm kgm
7/16-20UNF 15 1.53 M12 x 1.5 20 2.04
1/2-20UNF 20 2.04 M14 x 1.5 30 3.06
9/16-18UNF 25 2.55 M27 x 1.5 90 9.18
3/4-16UNF 72 7.34
7/8-14UN 127 12.95
11/16-12UN 147 14.99
13/16-12UN 173 17.64
15/16-12UN 198 20.19
15/8-12UN 320 32.63
17/8-12UN 390 39.77
WA320, 320PZ-6 50-500 29

(2) SEAL-LOCK - sealing nuts
Tightening torque
Thread
Nm kgm
M6 10 1.02
M6 x 0.5 11 1.12
M8 22 2.24
M8 x 1 24 2.45
M10 40 4.08
M10 x 1 44 4.49
M12 69 7.04
M12 x 1.5 72 7.34
M14 110 11.22
M14 x 1.5 120 12.24
M16 170 17.34
M16 x 1.5 180 18.35
50-500 30 WA320, 320PZ-6

(3) Oval head screw

Oval head screw with inner TORX, thread
precoated with Precote 80
Tensile strength class

10.9 11.9
Thread
Tightening torque
Nm kgm Nm kgm
M3 2.1 0.21 --- ---
M4 4.7 0.48 --- ---
M5 9.1 0.93 9.5 0.97
M6 15.8 1.61 --- ---
M8 37.7 3.84 --- ---
WA320, 320PZ-6 50-500 31

SEN04205-00 Removal and installation of HST motor 1 assembly
Removal and installation of HST 4. Disconnect port T1 hose (4) and port T2 hose
motor 1 assembly 1
(5).
5. Disconnect port A hose (6) and port B hose
Removal (7).
rear frames.

leakage.
a Put tags to the disconnected hoses and pipes k When the mounting bolts are removed,
and record the installed positions etc. on them. emergency circuit (8) may fall since it is
installed to motor 1 with the hose mounting
bolts. Take care.
1. Drain the hydraulic oil.
2. Disconnect front drive shaft (1) from the trans-

fer side. [*1]
6. Support motor 1 assembly (9) with tool [1]

placed on the transmission jack and remove 4
motor 1 mounting bolts. [*2]
7. Supporting motor 1 assembly (9) with the
hand, lower the transmission jack gradually to
remove motor 1 assembly (9).
3. Disconnect wiring connectors (T06) (2) and
(T11) (3) from HST motor 1. 4 Motor 1 assembly: 60 kg
50-500 32 WA320, 320PZ-6

Removal and installation of HST motor 1 assembly SEN04205-00
Installation
removal.
[*1]
59 74 Nm {6.0 7.5 kgm}
[*2]
3 Motor 1 assembly mounting bolt:
245 309 Nm {25.0 31.5 kgm}

again.
WA320, 320PZ-6 50-500 33

SEN04205-00 Removal and installation of HST motor 2 assembly
Removal and installation of HST 4. Disconnect port T1 block and hose (4) and port
motor 2 assembly 1
T2 block and hose (5).
Removal 5. Disconnect port A hose (6) and port B hose

k Stop the machine on a level ground and set (7).
rear frames.

leakage.
a Put tags to the disconnected hoses and pipes
and record the installed positions etc. on them. 6. Support motor 2 assembly (8) with tool [1]
placed on the transmission jack and remove 4
1. Drain the hydraulic oil. motor 2 mounting bolts. [*2]
7. Supporting motor 2 assembly (8) with the
hand, lower the transmission jack gradually to
2. Disconnect front drive shaft (1) from the trans- remove motor 2 assembly (8).
fer side. [*1]
4 Motor 2 assembly: 60 kg
3. Disconnect wiring connectors (T07) (2) and

(T10) (3) from HST motor 2.
50-500 34 WA320, 320PZ-6

Removal and installation of HST motor 2 assembly SEN04205-00
Installation
removal.
[*1]
59 74 Nm {6.0 7.5 kgm}
[*2]
3 Motor 2 assembly mounting bolt:
245 309 Nm {25.0 31.5 kgm}

again.
WA320, 320PZ-6 50-500 35

SEN04205-00 Disassembly and assembly of HST motor assembly
Disassembly and assembly of 2. EP servo valve assembly and cover (HST

HST motor assembly 1
motor 1)
Special tools
New/Remodel
Necessity
Sketch
Sym-
Q'ty
Part No. Part name
bol
CJW12101
4 02010-20783 Bolt q 1
790-201-2740 Push tool t 1
S
5 793T-417-1120 Push tool q 1
02010-20783 Bolt q 1
Disassembly
1. Seal
1) Protect drive shaft (1) with a tape etc.
2) Remove snap ring (2) and shim (3).
CJW11980
1) Remove 4 mounting bolts and solenoid

valve and housing assembly (5).
a Take care of the spring which may
jump out.
3) Tighten screws [1] into the holes of shaft
seal (4) blocked with rubber.
4) Pull out shaft seal (4) with pliers.
CJW11982
CJW11981
50-500 36 WA320, 320PZ-6

Disassembly and assembly of HST motor assembly SEN04205-00
2) Remove spring seat (7) and spring (8) 6) Cover

from port plate (6). 1] Remove cover (25).
3) Remove spring seat (9) and spring (12). 2] Remove plug (26) from cover (25).
4) Remove spring seat (11) and spring (10).
CJW11987
CJW11983
3. HA servo valve and directional shuttle valve

5) Disassemble the solenoid and housing assembly and flushing valve assembly
assembly (5). (HST motor 2)
1] Remove caps (14), coil (15) and snap
ring (16) of the solenoid in order.
CJW12104
CJW12163
2] Remove spool (18) and bushing (19)

from housing (13).
3] Remove pin (20).
a Do not remove nut (21) and screw
(22).
4] Remove plugs (24) from housing
(13).
a Do not remove plug (23).
CJW12103
WA320, 320PZ-6 50-500 37

1) Remove the 4 mounting bolts and sole- 4) Disassemble 2 solenoids and housing
noid valve and housing assembly (27) assembly (27).
from port plate (6). 1] Remove caps (36) and (37), coils (38)
a Take care of the spring which may and (39), and bushing (40) of the
jump out. solenoid in order.
CJW12105 CJW12106
2) Remove spring seat (29) and spring (30)

from port plate (6).
3) Remove spring seat (31) and spring (34).
CJW12125
a Disassemble the housing assembly

2] Remove snap ring (43), control bush-
ing (44), and control piston (45) from
housing (35).
3] Remove pin (46).
a Do not remove nut (47) and screw
(48).
CJW12108
50-500 38 WA320, 320PZ-6

4] Remove control piston (49) and

spring (50) from housing (35).
5] Remove plug (51).
a Do not remove 5 plugs (52).
CJW12107
5) Remove flushing valve assembly (53)

from port plate (6).
CJW12112
WA320, 320PZ-6 50-500 39

6) Disassemble flushing valve assembly (53)

2] Remove spring (55), plunger (56), ori-
fice (57), and snap ring (58).
3] Remove 2 plugs (59).
4] Remove spring (60), spring seat (61),
and spool (62).
6] Remove guide (64), orifice (65), and
guide (66).
CJW12164
50-500 40 WA320, 320PZ-6

4. Preparation of removal of port plate assem-

bly (6)
(Common to HST motors 1 and 2)
1) Break and remove plastic cap (71) and
check installed dimension (a) of Minimum
Flow Rate Adjustment screw (67).
CJW12111
CJW12165
6) Insert screw [6] to Maximum Flow Rate

Adjustment screw and fix rotary group
(70).
Screw [6]: M12 100 mm or longer.
2) Loosen locknut (68) and remove Minimum

3) Push piston (69) to set the angle of rotary
group (70) to 0.
4) Break and remove plastic cap (71) and CJW12126
check installed dimension (b) of Maximum
5) Remove Maximum Flow Rate Adjustment
screw (96).
a Plastic cap (71) is used to prevent
rusting. Since a spare for it is not sup-
plied, apply paint or take another rust-
preventive measure after assembling.
WA320, 320PZ-6 50-500 41

7) Make match marks (c) between port plate a Check of port plate
(6) and housing (82). q Sliding surface and side guides free
8) Remove port plate assembly (6). of scoring and no wear.
CJW12115 CJW12002
5. Disassemble port plate (6) assembly according a Check of control plate

to the following procedure. Faces smooth and even, free of cracks
1) Remove control lens (80). and scoring.
2) Remove bolt (73) and piston (74).
a Do not remove screw (76), rod (72), and
piston (69).
CJW12039
CJW12113
6. Removal of shaft and rotary group assem-

bly (81)
1) Remove O-ring (75).
3) Screw a bolt of M4 and pull out valve 2) Screw [2] in threaded pin into center pin
guide (77). (d).
4) Remove poppet (78). a Fix the cylinder with disc and locknut.
5) Remove valve seat (79). q Screw size: M6 92 mm
3) Remove screw [6].
CJW12119
CJW12127
50-500 42 WA320, 320PZ-6

4) Push the shaft end with a press to remove a Check of housing

shaft and rotary group assembly (81) from q Sliding surface and slide guides
housing (82). free of scoring and no wear
k If the bearings are used again, do
not hit on the drive shaft.
a Since shaft and bearing are used as

an assembly, do not remove the bear-
a If a press is not available, push the shaft ing.
end with tool [3] or [4] to remove rotary
group assembly (81). 7. Disassembly of rotary group assembly (70)
2) Remove cylinder block (83).
3) Remove shim (84) from cylinder block

(83).
WA320, 320PZ-6 50-500 43

a Check of cylinder block (83) a Check of piston and center pin

q Bores free of scoring, no evi- q No scoring and no pittings
dence of wear.
CJW12014
CJW12010
a Do not disassemble the drive shaft and

4) Remove retaining ring assembly (85). bearing assembly (89). (If the drive shaft
a Screws are glued. Warm it up to max. and be ar i ng a ss e mb ly i s de fe c ti ve ,
120C and remove with Torx-tools. replace it whole.)
5) Remove 7 pistons (86), spring (87), and
center pin (88) from shaft and bearing
assembly (89).
CJW12116
CJW12128
a Check of retaining ring (85)

q No scoring and no evidence of
wear
CJW12013
50-500 44 WA320, 320PZ-6

Assembly 4) Insert the piston to the end of cylinder

a Clean the all parts and remove burrs, etc. block (83) and secure it with screw [2].
a Coat the rotary parts and sliding parts with
engine oil (for details, see Table of fuel, cool-
ant and lubricants) before installing.
a If the tightening torque of a mounting bolt, nut,
or plug is not shown in this manual, see the
CJW12022
1. Assembly of rotary group assembly (70)
a If the drive shaft and bearing assembly
(89) is defective, replace it whole. (The
parts of this assembly cannot be supplied
loose.)
1) Install 7 pistons (86), center pin (88), and
spring (87) to the drive shaft and bearing
assembly (89). 5) Set bolt S4 to the shaft and rotary group
2) Install retaining ring assembly (85) with assembly (81) and protect the drive shaft
the screw. by type.
a For the tightening torque of the screw, a Threads of shaft: 7/16-14UNC-2B,
see Tightening torque table. Thread depth: 28 mm
CJW12128 CJW12169
3) Insert shim (84), center pin (88), and pis- 2. Installation of rotary group assembly
ton (86) in cylinder block (83). 1) Heat housing (82) to 80C.
a Make sure all parts are fitted in cor-
rectly.
CJW12024
CJW12021
WA320, 320PZ-6 50-500 45

2) Insert shaft and rotary group assembly 3. Port plate assembly (6)
(81) into housing (82) to seat position. 1) Assemble port plate assembly (6) accord-
ing to the following procedure.
1] Install valve seat (79).
2] Install poppet (78).
3] Install valve guide (77).
CJW12117
CJW12119
3) Insert screw [6] (M12 100 mm or

longer). (Fix the tapered part of cylinder
block (83) and set the angle to 0.)
5) Install O-ring (75) to the housing. a Piston (69), rod (72) and screw (76)
are already in the port plate (6).
4] Install piston (74) and bolt (73).
5] Thinly apply grease to control plate
(80), and then install it to the sliding
surface of the port plate assembly (6).
CJW12118
CJW12113
50-500 46 WA320, 320PZ-6

a Take care of assembly design!

2) Install port plate assembly (6) to housing
(82), matching marks (c) made when it
was removed.
CJW12122
CJW12115
4. Installation of Minimum Flow Rate Adjust-

ment screw (67) and Maximum Flow Rate
Adjustment screw (96).
1) Remove screw [6] and set Maximum Flow
Rate Adjustment screw (96).
Dimension (b) is the value measured at
the time of disassembly.
a When bolt is changed
q Since the bolt is used to plug the
hole simply, do not replace it with
long one.
2) Swivel rotary group (70) to starting posi-
tion.
3) Set Minimum Flow Rate Adjustment screw
(67) to dimension (a).
a Dimension (a) is important for all the
type.
a Tighten fixing screws (67) and (96)
with torque.
WA320, 320PZ-6 50-500 47

5. HA servo valve and directional shuttle valve 3] Install spool (62), spring seat (61),
assembly and flushing valve assembly (53) and spring (60).
(HST motor 2) 4] Install 2 plugs (59).
1) Assemble the flushing valve assembly 3 Plug: 40 Nm {4.1 kgm}
according to the following procedure. 5] Install snap ring (58), orifice (57),
1] Install guide (66), orifice (65), and plunger (56), and spring (55).
guide (64). 6] Install plug (54).
3 Guide (66): 3 Nm {0.31 kgm} 3 Plug: 50 Nm {5.1 kgm}
3 Guide (64): 8 Nm {0.81 kgm}
2] Install plug (63).
3 Plug:
29 38 Nm {2.96 3.89 kgm}
CJW12164
50-500 48 WA320, 320PZ-6

2) Install flushing valve assembly (53) to port 6] Install 2 solenoids to housing (35).
plate (6). a Install bushing (40), coils (39) and
3 Plug: (38), and caps (37) and (36) of the
55 60 Nm {5.61 6.12 kgm} solenoid in order.
CJW12112 CJW12106
3) Assemble housing assembly (27) accord-

ing to the following procedure.
1] Install plug (51) to housing (35).
2] Install spring (50) and control piston
(49) to housing (35).
a 5 plugs (52) are already in the hous-
ing (35).
CJW12107 4) Install spring (34) and spring seat (31) to

the port plate.
5) Install spring (30) and spring seat (29).
3] Install pin (46).

4] Install control piston (45) and control
CJW12125
bushing (44).
5] Install snap ring (43).
CJW12108
WA320, 320PZ-6 50-500 49

6) Install solenoid valve and housing assem- 2) Assemble housing assembly (5) according
bly (27) with the 4 mounting bolts to port to the following procedure.
plate (6). 1] Install plug (24) to housing (13).
2] Install pin (20).
3] Install bushing (19) and spool (18) to
housing (13).
a Plugs (23) are already in the housing
(13).
CJW12105
CJW12103
6. EP servo valve assembly and cover

(HST motor 1)
1) Cover
1] Install plug (26) to cover (25).
3 Plug:
29 38 Nm {3.0 3.9 kgm} 4] Install snap ring (16), coil (15), and
2] Install cover (25). cap (14) in order to housing assembly
3 Mounting bolt: (13).
39 49 Nm {4.0 5.0 kgm}
CJW12102
CJW11987
50-500 50 WA320, 320PZ-6

3) Install spring (10) and spring seat (11) to 5) Protect drive shaft (1) with a tape etc.
port plate (6). 6) Install snap ring (2).
CJW11980
CJW11983
8. Filling with oil

Fill up hydraulic aggregates with medium
6) Install solenoid valve and housing assem- before start-up.
bly (5) with the 4 mounting bolts.
CJW12036
CJW11982
9. Tightening torque table

7. Seal (Common to HST motors 1 and 2) a If the tightening torque of a mounting bolt, nut,
1) Before setting seal (4), measure depth (f) or plug is not shown in this manual, see Disas-
to the groove bottom of snap ring (2). sembly and assembly of HST pump assembly,
2) Make a mark of insertion depth (e) of push Tightening torque table.
tool S5, (f) + thickness of shim (3), on
push tool S5. 10. Before starting
3) Using push tool S5, press fit seal (4). a Observe the operating instructions before
4) Install shim (3). starting.
q Check the machine for remarkable faults.
q Do not operate the machine with defective
instruments, warning lights or control ele-
ments.
q All safety devices must be in a secure
position.
CJW12170 q Do not carry with you movable objects or
secure them to the machine.
q Keep oily and inflammable material away
from the machine.
q Before entering the operators cab, check
if persons or obstacles are beside or
beneath the machine.
q Be careful when entering the operators
cab, use stairs and handles.
q Adjust your seat before starting.
WA320, 320PZ-6 50-500 51

SEN04205-00 Removal and installation of work equipment control valve assembly
Removal and installation of work 3. Disconnect the following hoses and tubes. [*1]
equipment control valve a Mark all the hoses and tubes with tags to
prevent mistakes in the mounting position
assembly 1
when installing.
Removal a Plug the disconnected hoses to prevent oil
k Stop the machine on a level ground and, leakage.
apply the parking brake, and put chocks a Since oil will leak through the discon-
under the tires. nected hoses and tubes, prepare oil
k Support the lift arm securely. receivers.
k Stop the engine, and then slowly loosen the q (2): Port A1 hose
oil filler cap of the hydraulic tank to release q (3): Port B1 hose
the residual pressure in the hydraulic tank. q (4): Port A2 tube
k Operate the work equipment control lever 2 q (5): Port B2 tube
3 times to release the residual pressure in q (6): Bucket DUMP PPC hose
the work equipment circuit. q (7): Bucket TILT PPC hose
q (8): Lift arm LOWER PPC hose
1. Raise the lift arm, dump the bucket, and sup- q (9): Lift arm RAISE PPC hose
port the lift arm with support stand [1] and q (10): Port P hose
square bar [2]. q (11), (12): Port T hoses
Reference: This is the view from the rear lower

2. Remove the work equipment control valve upper part of the work equipment control valve.
cover (1).
50-500 52 WA320, 320PZ-6

Removal and installation of work equipment control valve assembly SEN04205-00
4. Remove 3 mounting bolts (13) and move work Installation

equipment control valve (14) toward you. q Carry out installation in the reverse order to
removal.
[*1]
a Connect PPC hoses (6) (9) according to their
band colors as shown below.
a Connect each PPC hose having an even No.
to the rear of the PPC hose having a corre-
sponding odd No. on the work equipment
valve: Connect (6) to the rear of (7), (8) to the
rear of (9).
q Work equipment lever specification: 2-lever
q Work equipment lever specification: Mono-
lever (If equipped)
No. Connecting point Band color
5. Lift off work equipment control valve assembly
(15). (6) Bucket DUMP Blue
4 Work equipment control valve assem- (7) Bucket TILT Red

bly: 65 kg (8) Lift arm LOWER Orange
(9) Lift arm RAISE Yellow

again.
WA320, 320PZ-6 50-500 53

SEN04205-00 Removal and installation of hydraulic tank assembly
Removal and installation of 4. Remove tube (4) from the hydraulic oil filter.
hydraulic tank assembly 1
5. Remove hydraulic oil filter cover mounting
Removal bolts (5) and move hydraulic oil filter and cover
k Stop the machine on a level ground and set assembly (6) and its hoses to under the opera-
the lock bar to the frame to fix the front and tor's cab.
rear frames.
k Operate the work equipment control lever 2
3 times to release the residual pressure in
the work equipment circuit.

leakage.
a Put tags to the disconnected hoses and pipes
and record the installed positions etc. on them.
1. Remove hydraulic tank upper cover (1).

k Slowly loosen the oil filler cap of the 6. Disconnect 8 hoses (7), (8), (9), (10), (11),
hydraulic tank to release the residual (12), (13), and (14) from the hydraulic tank. [*1]
pressure in the hydraulic tank.
2. Remove cab right undercover (2).
3. Remove right side fender (3).

4 Fender: 35kg
50-500 54 WA320, 320PZ-6

Removal and installation of hydraulic tank assembly SEN04205-00
7. Sling the hydraulic tank assembly temporarily Installation

and remove 1 upper mounting bolt and 2 lower q Carry out installation in the reverse order to
mounting bolts (15). [*2] removal.
[*1]
2 Inserting parts of hoses (6) and (7):
Gasket sealant (ThreeBond 1206E or
equivalent)
3 Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
[*2]
3 Hydraulic tank mounting bolt:
98 123 Nm {10.0 12.5 kgm}

8. Lift off hydraulic tank (16) and ladder together. level. Run the engine to circulate the oil
4
Hydraulic tank and ladder assembly:
again.
210 kg (including hydraulic oil)

WA320, 320PZ-6 50-500 55

SEN04205-00 Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of Disassembly

hydraulic cylinder assembly 1 1. Cylinder assembly
Set cylinder assembly (1) to tool U1.
Special tools
2. Cylinder head and piston rod assembly
New/Remodel
Necessity
(Steering cylinder)
Sketch
Sym-
Q'ty
Part No. Part Name 1) Using tool U2, remove cylinder head (2)
bol
from the cylinder.
790-502-1003 Repair stand t 1

1
790-101-1102 Hydraulic pump t 1
790-102-2303
Wrench assembly
2 or t 1
(for steering)
790-102-3802
3 790-302-1340 Socket (for steering) t 1
790-101-5021 Grip 1
01010-50816 Bolt 1
4 790-201-1821 Push tool (lift) 1

Push tool 2) Pull cylinder head and piston rod assem-
790-201-1831 1
(bucket) bly (3) out of cylinder (4).
Push tool a Since oil will flow out when the piston
790-201-1741 1 rod assembly is pulled out of the cyl-
(steering)
inder, prepare an oil receiver.
U
790-101-5021 Grip 1
01010-50816 Bolt 1
5
790-201-1630 Plate (lift) 1
790-201-1640 Plate (bucket) 1
790-201-1550 Plate (steering) 1
6 790-720-1000 Expander q 1
796-720-1680 Ring (lift, bucket) q 1
Clamp
07281-01589 q 1
7 (lift, bucket)
796-720-1740 Ring (steering) q 1
07281-00809 Clamp (steering) q 1
Wrench assembly
790-102-4300 t 1
8 (lift, bucket)
790-102-4310 Pin t 2
50-500 56 WA320, 320PZ-6

Disassembly and assembly of hydraulic cylinder assembly SEN04205-00
3. Cylinder head and piston rod assembly 4. Piston and cylinder head (Steering cylin-
(Bucket cylinder and lift cylinder) der)
1) Remove the mounting bolt of cylinder 1) Set cylinder head and piston rod assembly
head assembly (2). (3) to tool U1.
q Width across flats of bolt: 24 mm 2) Using tool U3, remove nut (5).
q Width across flats of nut (Steering):
46 mm
3) Remove piston assembly (6) and cylinder
head assembly (2).
2) Pull cylinder head and piston rod assem-

bly (3) out of cylinder (4).
a Since oil will flow out when the piston
rod assembly is pulled out of the cyl-
inder, prepare an oil receiver.
WA320, 320PZ-6 50-500 57

5. Piston and cylinder head (Bucket cylinder 6. Disassembly of piston assembly

and lift cylinder) 1) Remove wear ring (9) and piston ring (10)
1) Set cylinder head and piston rod assembly from piston (8).
(3) to tool U1.
2) Remove lock screw (18) from the piston
rod assembly.
a Screw size: M12 x 1.75
a If screw (18) is so caulked that it can-
not be removed, tighten it and apply a
ta p to t he th r ead s o f the p is to n
assembly, and then remove it.
3) Using tool U8, remove piston assembly
(6).
a When not using tool U8, loosen the
piston assembly by using 2 holes (A).
q Hole (A): 10 mm
4) Remove cylinder head assembly (2).
a For only the bucket cylinder and lift
cylinder.
2) Remove O-ring and backup ring (11) from
position (8).
50-500 58 WA320, 320PZ-6

7. Disassembly of cylinder head assembly Assembly

1) Remove O-ring and backup ring (15). a Take care not to damage the packings, dust
2) Remove snap ring (16) and dust seal (17). seals, and O-rings, etc.
3) Remove rod packing (18). a Do not insert each backup ring forcibly, but
4) Remove buffer ring (19). warm it in water at 50 60C and then insert it.
5) Remove bushing (20).
6) Remove O-ring (21). (For only the steering 1. Assembly of cylinder head assembly
cylinder) 1) Using tool U4, press fit bushing (20).
a Bucket cylinder and lift cylinder 2) Install buffer ring (19).
3) Install rod packing (18).
4) Using tool U5, install dust seal (17) and
secure it with snap ring (16).
5) Install backup ring and O-ring (15).
6) Install O-ring (21). (For only the steering
cylinder.)
a Steering cylinder
WA320, 320PZ-6 50-500 59

2. Assembly of piston assembly 3. Assembly of cylinder head and piston rod

1) Using tool U6, expand piston ring (10). assembly (Steering cylinder assembly)
a Set the tool to the piston ring and turn 1) Set cylinder head and piston rod assembly
its handle by 8 10 turns to expand (3) to tool U1.
the piston ring. 2) Install cylinder head assembly (2) and pis-
ton assembly (6) to the piston rod.
3) Using tool U3, tighten nut (5) to the speci-
fied torque.
a Degrease and clean the threads of
nut (5) and piston rod.
2 Threads of piston rod:
Liquid adhesive (LOCTITE No.
262 or equivalent)
q Width across flats of nut: 46 mm

3 Nut (Steering):
785 78.5 Nm {80 8.0 kgm}
2) Remove piston ring (10) from tool U6 and

install it to piston (8).
3) Using tool U7, shrink piston ring (10).
4) Install wear ring (9).
4. Assembly of cylinder head and piston rod

assembly (Bucket cylinder and lift cylinder)
1) Set piston rod (3) to tool U1.
2) Install cylinder head assembly (2).
q When reusing the rod and piston
assembly, assemble them according
a For only the bucket cylinder and lift to the following procedure.
cylinder. 3) Using tightening tool U8, tighten piston
5) Install backup ring and O-ring (11). assembly (6) until the screw holes are
aligned.
Go to 6).
q When replacing either or both of the
rod and piston, assemble the new
parts according to the following pro-
cedure.
4) Using tool U8, install piston assembly (6).
3 When threading lock screw:
294 29.4 Nm {30 3 kgm}
a When not using tool U8, loosen the
piston assembly by using 2 holes (A).
q Hole (A): 10 mm
50-500 60 WA320, 320PZ-6

5. Cylinder head (Steering cylinder)

1) Set cylinder (4) to tool U1.
2) Sling cylinder head and piston rod assem-
bly (3) and install cylinder (4).
5) Make 1 screw hole to install screw (18).

a Make 1 hole horizontally with a drill at
the V-groove of the threaded parts of
piston assembly (6) and rod (3).
3) Using tool U2, install cylinder head
Diameter of Depth of tap Tap to be Tapping
assembly (2) to the cylinder.
3 Cylinder head:
tap drill hole drill hole used depth
10.3 27 12 X 1.75 20 539 54.0 Nm {55 5.5 kgm}
4) Remove cylinder assembly (1) from tool
U1.
6) Install lock screw (18) and caulk 4 points
around it with a punch.
a Degrease and clean the fitting part of
the lock screw.
2 Threads of lock screw:
Liqui d ad he sive (L OCTITE
No. 262 or equivalent)
3 Lock screw:
58.9 73.6 Nm {6 7.5 kgm}
WA320, 320PZ-6 50-500 61

6. Cylinder head (Bucket cylinder and lift cyl-

inder)
1) Set cylinder (4) to tool U1.
2) Sling cylinder head and piston rod assem-
bly (3) and install cylinder (4).
3) Install cylinder head assembly (2) to the
cylinder.
3 Cylinder head (Bucket):
250 24.5 Nm {25.5 2.5 kgm}
3 Cylinder head (Lift):
162 14.5 Nm {16.5 1.5 kgm}
a For only the bucket cylinder

4) Adjust the leveler plate to the following
dimensions and tighten the bolt.
Dimension (a): 48 1 mm
Dimension (b): 119 2 mm
5) Remove cylinder assembly (1) from tool

U1.
50-500 62 WA320, 320PZ-6

WA320, 320PZ-6 50-500 63

SEN04205-00

2008 KOMATSU
All Rights Reserved
50-500 64
SEN04206-00
WA320-6
WA320PZ-6
WA320-6 70001 and up

600 Work equipment

Removal and installation of work equipment assembly .................................................................................. 2
WA320, 320PZ-6 50-600 1

600 Work equipment
SEN04206-00 Removal and installation of work equipment assembly
Removal and installation of work 3. Move the machine to the rear and disconnect
equipment assembly 1
the bucket.
Removal 4. Sling bucket cylinder assembly (3) temporarily

k Stop the machine on a level ground and set and pull out rod-side pin (4) to disconnect the
the lock bar to the frame to fix the front and cylinder rod and bell crank. [*3]
rear frames. a Install block [1] between the cylinder bot-
k Lower the work equipment to the ground, tom and frame.
stop the engine, apply the parking brake, a Record the thickness and quantity of the
and put chocks under the tires. shims.
k
4
Disconnect the cable from the negative ()
Bucket cylinder assembly: 130 kg
1. Sling the bucket link temporarily and remove

bucket link pin (1). [*1]
4 Bucket link assembly: 45 kg
a Secure the bucket link to the bell crank
with chains, etc.
shims.
2. Remove bucket hinge mounting pin (2). [*2]

k Never insert your fingers in the pin
holes.
shims.
5. Set supports [2] under the end of the lift arm
and release the residual pressure in the
hydraulic piping.
50-600 2 WA320, 320PZ-6

600 Work equipment
Removal and installation of work equipment assembly SEN04206-00
6. Sling lift cylinder assembly (6) temporarily and

remove mounting pin (5). [*4]
shims.
a When lowering the lift cylinder assembly,
put a block on the top of axle.
4 Lift cylinder assembly (1 piece):
110 kg
11. Sling bucket link assembly (12) temporarily,

pull out mounting pin (13), and remove the
bucket link assembly from the bell crank
assembly. [*7]
4 Bucket link assembly: 45 kg
7. Disconnect boom kick-out proximity switch

connector CN-F04 (7).
8. Remove boom kick-out switch (8). [*5]
12. Sling bell crank assembly (14) temporarily and

pull out mounting pin (15). [*8]
13. Lift off bell crank assembly (14).

4 Bell crank assembly: 260 kg
9. Sling lift arm and bell crank and bucket link

assembly (10) temporarily and pull out mount-
ing pin (11). [*6]
shims.
10. Lift off lift arm, bell crank and bucket link
assembly (10).
4 Lift arm, bell crank and bucket link
assembly: 1250 kg
WA320, 320PZ-6 50-600 3

600 Work equipment
14. Pull dust seal (17) and bushing (18) out of lift Installation
arm (16). [*9] q Carry out installation in the reverse order to
removal.
k When starting the engine, check that the
directional lever is in neutral and the park-
ing brake is applied.
k When aligning the pin holes, use a bar.
Never insert your fingers in the pin holes.
a Apply specified lubricant to the seal so that the
seal will not be damaged when the pin is
inserted.
a Supply grease to each pin until it comes out
through the joint.
[*1]
Procedure for installing bucket link pin
15. Pull dust seal (19) and bushing (20) out of bell 1. Sling the bucket link assembly and install cord
crank (14). [*9] ring (23), aligning the holes for mounting pin
(1).
2. Insert shims on both sides so that clearances

(a) on both sides will be the same.
q Clearance (a) (On each side): Max. 1.5
mm
q Varieties of shim thickness: 1.5, 3.0 mm
3. Install mounting pin (1) and lock it with bolt

(24).
holes.
a Take care that the cord ring will not be
caught.
16. Pull dust seal (21) and bushing (22) out of
bucket link assembly (12). [*9]
50-600 4 WA320, 320PZ-6

600 Work equipment
[*2] [*3]
Procedure for installing bucket hinge pin Procedure for installing bucket cylinder pin (on
1. Operate the control lever to align the holes for rod side)
bucket mounting pin (2) and install cord ring a It is not necessary to insert a shim in clearance
(25). (C).
1. Install mounting pin (4) and lock it with bolt
2. Insert a shim in clearance (b). (27).
q Clearance (b) (On each side): Max. 1.5 k Never insert your fingers in the pin
mm holes.
q Varieties of shim thickness: 1.5, 3.0 mm a Take care not to damage the pin.
a Before installing the pin, apply lubricant to
3. Install mounting pin (2) and lock it with bolt the inside of the bushing.
(26). 2 Inside of bushing:
k Never insert your fingers in the pin Lubricant containing molybdenum
holes. disulfide (LM-P or equivalent)
a Take care that the cord ring will not be a After installing the pin, supply grease.
caught. 3 Grease: Hyper White (G2-T) or equiv-
a Take care not to damage the pin. alent
a Before installing the pin, apply lubricant to
the inside of the bushing.
2 Inside of bushing and seal:
Lubricant containing molybde-
num disulfide (LM-P or equiva-
lent)
a After installing the pin, supply grease.
2 Grease: Hyper White (G2-T) or
equivalent
2. Adjust the bucket positioner. For details, see

Testing and adjusting, Testing and adjusting
bucket positioner.
WA320, 320PZ-6 50-600 5

600 Work equipment
[*4] [*6]
Procedure for installing lift cylinder pin (on rod Procedure for installing lift arm pin (on frame
side) side)
k When starting the engine, check that the 1. Insert a shim in clearance (e).
directional lever is in neutral and the park- a When installing the right-hand lift arm pin,
ing brake is applied. fit the boss on the right inside of the frame
1. Insert a shim in clearance (d). to the lift arm boss to eliminate the clear-
q Clearance (d) (On each side): Max. 1.5 ance and insert shims in the clearance on
mm the opposite side.
q Varieties of shim thickness: Only 1.5 mm a When installing the left-hand lift arm pin,
insert shims evenly on both sides.
2. Install mounting pin (5) and lock it with bolt q Clearance (e) (On each side): Max. 1.5
(28). mm
k Never insert your fingers in the pin q Varieties of shim thickness: 1.5, 3.0 mm
holes. 2. Install mounting pin (11) and lock it with bolt
a Take care not to damage the pin. (29).
a Before installing the pin, apply lubricant to k Never insert your fingers in the pin
the inside of the bushing. holes.
2 Inside of bushing: a Take care not to damage the pin.
Lubricant containing molybde- a Before installing the pin, apply lubricant to
num disulfide (LM-P or equiva- the inside of the bushing.
lent) 2 Inside of bushing:
a After installing the pin, supply grease. Lubricant containing molybde-
2 Grease: Hyper White (G2-T) or num disulfide (LM-P or equiva-
equivalent lent)
equivalent
[*5]
a Adjust the boom kick-out. For details, see Test-
ing and adjusting, Testing and adjusting of
boom kick-out switch.
50-600 6 WA320, 320PZ-6

600 Work equipment
[*7] [*8]
Procedure for installing bucket link pin Procedure for installing bell crank center pin
a It is not necessary to insert a shim in clearance a It is not necessary to insert a shim.
(f). 1. Install the mounting pin and lock with the bolt.
q Clearance (f) (On each side): Max. 1.5 k Never insert your fingers in the pin
mm holes.
a Secure the bucket link to the bell crank with a Take care not to damage the pin and seal.
chains, etc. a Before installing the pin, apply lubricant to
1. Install cord ring (30), aligning the holes for the inside of bushing and seal.
bucket link mounting pin (13). 2 Inside of bushing and seal:
Lubricant containing molybde-
2. Install mounting pin (13) and lock it with bolt num disulfide (LM-P or equiva-
(31). lent) or Hyper White (G2-T)
holes. [*9]
a Take care that the cord ring will not be a Press fit bushings (18), (20), and (22) to lift arm
caught. (16), bell crank (14), and bucket link (12)
a Take care not to damage the pin. respectively with hydraulic cylinder [3] and
a Before installing the pin, apply lubricant to then install dust seals.
the inside of the bushing. 2 Bushing: Grease (G2-LI)
2 Inside of bushing: a Apply the grease to the seals to prevent their
Lubricant containing molybde- damages.
num disulfide (LM-P or equiva-
lent)
equivalent
a Press fit the dust seals with the lips out.

q Installed dimension (g): 0.25 0.80 mm
q Installed dimension (h): 2 3 mm
q Greasing
Supply grease to each pin.
a Supply grease until it comes out of
the joint.
WA320, 320PZ-6 50-600 7

SEN04206-00

2008 KOMATSU
All Rights Reserved
50-600 8
SEN04207-00
WA320-6
WA320PZ-6
WA320-6 70001 and up


Removal and installation of operator's cab and floor frame assembly............................................................ 2
Removal and installation of operator's cab glass (Stuck glass) ...................................................................... 8
Disassembly and assembly of operator's seat assembly.............................................................................. 16
Removal and installation of air conditioner unit ............................................................................................ 26
WA320, 320PZ-6 50-700 1

SEN04207-00 Removal and installation of operator's cab and floor frame assembly
Removal and installation of 3. Open and fix right engine side cover (1).
operator's cab and floor frame a Check that the cover is locked securely.
assembly 1
4. Remove right fender (2).
Removal 4 Fender: 35 kg

the atmosphere.
k If the refrigerant (R134a) gets inside of 5. Remove right covers (3), (4) and (5).
Therefore, make sure to wear protec- 6. Remove hydraulic tank cover (6).
tive glasses when collecting or filling k Loosen the hydraulic tank cap gradu-
the refrigerant. Collecting and filling ally to release the pressure in the
work must be conducted by a qualified hydraulic tank.
person.
a The operator's cab of this machine forms one

unit with the floor frame.
1. Recover the refrigerant (R134a). For details,
see Removal and installation of air conditioner
unit. [*1]
2. Drain the coolant from the radiator. 7. Disconnect cab ground cable (7) from the
6 Radiator: Approx. 26 l lower right of the floor.
8. Remove wiring harness clamp (8).
50-700 2 WA320, 320PZ-6

Removal and installation of operator's cab and floor frame assembly SEN04207-00
9. Disconnect the following wiring harness con-

nectors from the lower right of the floor.
q (9): CN-FL2
q (10): CN-FL1
q (11): CN-FL4
q (12): CN-FL3
14. Remove left fender (22).

4 Fender: 35 kg
10. Disconnect 6 PPC hoses (13).
11. Disconnect hose (14) from the brake valve.
12. Disconnect T port hose (15) from the Orbit-roll

valve.
15. Remove left covers (23), (24) and (25).
16. Remove air conditioner external air filter case

cover (26).
13. Disconnect the following hoses from Orbit-roll

valve (16). [*2]
q (17): LS port hose (Right)
q (18): P port hose (Left lower)
q (19): R port hose (Right lower)
q (20): L port hose (Right upper)
q (21): T port hose (Left upper)
(Since hose (21) was disconnected in
the previous step from the hydraulic
tank, it does not need to disconnect in
this step.)
leakage.
a Put tags to the disconnected hoses and
record the installed positions etc. on them.
WA320, 320PZ-6 50-700 3

17. Disconnect the following wiring harness con- 19. Disconnect 2 washer hoses (41) from the
nectors from the lower left of the floor. engine compartment side.
q (27): CN-LR1
q (28): CN-LR10 20. Disconnect air conditioner pipes (42) and (43).
q (29): CN-LR2 [*1]
q (30): CN-LR3
q (31): CN-LR12 21. Disconnect heater hoses (44) and (45) from
q (32): CN-LR4 the engine side.
q (33): CN-LT1 a Put tags on the disconnected hoses and
q (34): CN-LT12 record the installed positions etc. on them.
q (35): CN-LR7 a Plug the disconnected hoses to prevent oil
q (36): CN-LR11 leakage.
q (37): CN-LR6
a Put tags on the disconnected connectors
and record the installed positions etc. on
them.
22. Remove air conditioner pipe clamps (46) and

(47) from the lower left of the floor.
18. Remove wiring harness clamps (38), (39) and

(40).
50-700 4 WA320, 320PZ-6

23. Disconnect the following hoses from the top of 25. Set parking brake lever (53) in the OFF
brake valve (48). [*3] (Release) position.
q (49): A port hose
q (50): B port hose 26. Remove seat belt mounting bolt (54).
q (51): P1 port hose
27. Remove cover (55).
24. Disconnect the following hoses from brake
valve (46). [*3]
q (52): T2 port hose
q (53): PB port hose
q (54): PA port hose
leakage. AJF00729
a Put tags on the disconnected hoses and
record the installed positions etc. on them.
28. Loosen locknut (56) and remove pin (57).
29. Pull out grommet (58) and brake cable (59)

together toward under the floor.
AJF00729
WA320, 320PZ-6 50-700 5

30. Remove right and left front mount covers (60). Installation
31. Remove right and left rear fender brackets removal.
(61).
[*1]
not enter them.
a Check O-ring (70) for a flaw and deterioration.
a When connecting each refrigerant pipe, apply
compressor oil for new refrigerant (R134a)
(DENSO: ND-OIL8 or ZEXEL ZXL100PG
(equivalent to PAG46)) to O-ring (70).
3 Apply engine oil (EO15W-40) to threaded
part and seat of mounting bolt.
32. Remove right and left front operator's cab 12 15 Nm {1.2 1.5 kgm}
mounting nuts (62). [*4] 3 Threaded part of hose (M22 1.5):
20 25 Nm {2.0 2.5 kgm}
33. Remove right and left rear operator's cab 3 Threaded part of hose (M24 1.5):
mounting nuts (63). [*5] 30 35 Nm {3.0 3.5 kgm}
34. Lift off operator's cab and floor frame assembly q Charging with refrigerant (R134a)
(64). Charge the air conditioner circuit with refriger-
a Check that all the wirings and pipings are ant (R134a).
disconnected. a Charge capacity: 1,200 50 g
4 Operator's cab and floor frame assem- [*2]
bly: 900 kg Bleed air from the steering circuit. For details, see
Testing and adjusting, "Bleeding air from steering
circuit".
[*3]
Bleed air from the brake system. For details, see
Testing and adjusting, "Bleeding air from brake cir-
AJF00729 cuit".
[*4]
3 Right and left front operator's cab mounting
nuts (62): 824 1,030 Nm {84 105 kgm}
50-700 6 WA320, 320PZ-6

[*5]
3 Right and left rear operator's cab mounting
nuts (63): 824 1,030 Nm {84 105 kgm}

again.
5 Hydraulic oil (For details, see "Table of fuel,
coolant and lubricants"):

(For details, see "Table of fuel, coolant and
lubricants")
WA320, 320PZ-6 50-700 7

SEN04207-00 Removal and installation of operator's cab glass (Stuck glass)
Removal and installation of a If the glass is narrow, you may cut the
operator's cab glass (Stuck glass)1 adhesive by the following method. Insert a
fine wire [2] (piano wire, etc.) in the adhe-
Special tools sive and grip its both ends with pliers [3],
etc. (or hold them by winding them onto
New/Remodel
something) and cut the adhesive with the
Necessity
Sketch
wire.
Q'ty
1 793-498-1120 Clear plate t 2

1 2 793-498-1130 Plate t 2
X 3 793-498-1110 Magnet t 2
Lifter (Suction CPW11602
2 793-498-1210 cups) t 2
Removal
a All sides of each glass of the operator's cab of
this machine are stuck.
a Remove the window glass to be replaced
a The broken window glass may be
1. Using seal cutter [1], cut the adhesive between removed with knife [4] and a screwdriver.
broken window glass (1) and operator's cab (If the screwdriver is applied directly to the
(2). normal window glass, the glass will be
broken.)
a When using knife [4], insert a screwdriver
in the cut to widen it and move the knife
forward.
CPW11601
CPW11607
2. Remove the window glass.
50-700 8 WA320, 320PZ-6

Removal and installation of operator's cab glass (Stuck glass) SEN04207-00
Installation 3. When the adhesive was removed with the

1. Using scraper [5], remove the remaining adhe- scraper, if any paint was flaked off, coat the
sive. bare part with paint.
a Do not scratch the paint. a If the glass is installed without repairing
the bare part, that part will be rusted.
a Do not apply paint to the part which will be
coated with primer.
CPW11603
CPW11605
2. Remove oil, dust, dirt, etc. from the sticking

surfaces of cab (2) and window glass (3) with
white gasoline.
a If the sticking surfaces are not cleaned 4. Stick double-sided adhesive tape (4) along the
well, the glass may not be stuck perfectly. inside edge of the glass sticking section.
a Clean the all black part on the back side of q Size of double-sided adhesive tape:
the window glass. 7 4.8 mm
a After cleaning the sticking surfaces, leave a When sticking the double-sided adhesive
them for at least 5 minutes to dry. tape, do not touch the cleaned surface as
much as possible.
a Do not remove the release tape of the
double-sided adhesive tape on the glass
sticking side before sticking the glass.
CPW11604
CPW11606
WA320, 320PZ-6 50-700 9

a Take care the corner (part (b)) of double-

sided adhesive tape will not float.
CPW11614
CPW11633
3) Using tool X2 (suction cups), place win-

dow glass (3) on tool X1-1 (5 mm spacer)
a When sticking the double-sided adhesive and match it to the operator's cab.
tape around a side or a rear window glass,
start at center of the top and make a clear-
ance of about 5 mm at end joint (c).
CPW11615
CWW11608
4) Check the clearance between window

glass (3) and operator's cab (2) on both
sides and adjust it evenly.
5. Position the replacement glass. 5) Stick tape [6] between window glass (3)
1) Stick X1-2 (thin steel sheet) to tool X1-1 and operator's cab (2) and draw position-
(spacer) with adhesive. ing line (a).
q Spacer thickness ( t) : 5 mm 6) Cut the tape between window glass (3)
2) Match tool X1-3 (magnet) to tools X1-1 and operator's cab (2) with a knife, and
and X1-2 and set them to the 2 lower then remove the window glass.
places of the window glass sticking part of a Do not remove the tapes left on the
operator's cab (2). window glass and operator's cab
before installing the window glass.
CPW11613
CPW11616
50-700 10 WA320, 320PZ-6

6. Apply primer. a Parts to be coated with primer: Apply

a The expiration date of primer (5) is 4 the primer all over dimension (d) on
months after the date of manufacture. Do the outside of the double-sided adhe-
not use primer (5) after the expiration. sive tape.
a Use the primer within 2 hours after open- q Dimension to apply primer (d):
ing it. 23 mm
a Even if the primer is sealed again just after a After applying the primer, leave it for
it is opened, use it within 24 hours after it at least 5 minutes (within 8 hours) to
is opened for the first time. dry.
(Discard the primer 24 hours after it is a If the glass primer is applied by mis-
opened.) take, wipe it off completely with white
1) Stir the primers for paint and glass suffi- gasoline.
ciently before using them. (If wrong primer is applied, the glass
a If the primer has been stored in a will not be stuck.)
refrigerator, leave it at the room tem-
perature for at least half a day before
stirring it.
(If the primer is opened just after
taken out of the refrigerator, water will
be condensed. Accordingly, leave the
primer at the room temperature for a CPW11610
sufficient time.)
2) When reusing primer brush (6), wash it in
white gasoline.
a After washing the brush, check it
again for dirt and foreign matter.
a Prepare respective brushes for the
paint primer and glass primer.
CPW11609
3) Evenly apply paint primer (7) to the parts

on the outside of double-sided adhesive
tape (4) on operator's cab (2) which will be
coated with the adhesive.
2 Paint primer: SUNSTAR PAINT
PRIMER 580 SUPER
a Do not apply the primer more than 2
times.
(If it is applied more than 2 times, its
performance will be lowered.)
WA320, 320PZ-6 50-700 11

4) Evenly apply glass primer (8) to the black 7. Apply adhesive.

part of window glass (3) to be stuck. a Use either of the 2 types of the adhesive.
2 Glass primer: SUNSTAR GLASS 2 Adhesive (Summer):
PRIMER 580 SUPER SUNSTAR PENGUINE
a Do not apply the primer more than 2 SEAL 580 SUPER S
times. 2 Adhesive (Winter):
(If it is applied more than 2 times, its SUNSTAR PENGUINE
performance will be lowered.) SEAL 580 SUPER W
a Parts to be coated with primer: Apply a The expiration date of the adhesive is 4
the primer to the sticking surface of months after the date of manufacture. Do
window glass (3) and all over dimen- not use the adhesive after this limit.
sion (d) on double-sided adhesive a Keep the adhesive in a dark place where
tape (4) and operator's cab (2). the temperature is below 25C.
q Dimension to apply primer (d): a Never heat the adhesive higher than
23 mm 30C.
a Do not apply the primer to the a When reusing the adhesive, remove all
boarder about 5 mm wide between the hardened part from the nozzle tip.
the black part and transparent part of 1) Break aluminum seal (10) of the outlet of
the glass. adhesive cartridge (9) and install the noz-
a After applying the primer, leave it for zle.
at least 5 minutes (within 8 hours) to
dry.
a If the paint primer is applied by mis-
take, wipe it off completely with white
gasoline.
(If wrong primer is applied, the glass
will not be stuck.) CPW11612
CWW11625
2) Cut the tip of the adhesive nozzle (11) so
that dimensions ( f ) and (g) will be as fol-
lows.
q Dimension ( f) : 10 mm
q Dimension (g): 12 mm
CPW11617
CPW11611
50-700 12 WA320, 320PZ-6

3) Set adhesive cartridge (9) to caulking gun a Apply adhesive (12) to dimensions (h)
[7]. and ( j ) of both-sided adhesive tape
a An electric caulking gun is more effi- (4) of operator's cab (2).
cient. q Dimension (h): 10 mm
q Dimension ( j ) : 12 mm (Approx.
twice a s high as adhes iv e
tape)
a Apply adhesive (12) higher than both-
sided adhesive tape (4).
a Apply the adhesive evenly.
CPW11618
CWW11620
4) Remove release tape (13) of the double-

sided adhesive tape on the glass side.
8. Install window glass (3).

a If the glass is positioned wrongly, the
adhesive must be removed and cleaned,
and then the primer and adhesive must be
applied again. Accordingly, position the
glass carefully when sticking it.
1) Similarly to step 5, match tools X1-1, X1-
2, and X1-3 and set them to the 2 lower
places of the window glass sticking part of
operator's cab (2).
5) Apply adhesive (12) to the outside of both-
sided adhesive tape (4) of the operator's
cab.
a Before applying the adhesive, check
that the primer is applied to the sur-
face to which the adhesive will be
applied.
CPW11614
CPW11619
WA320, 320PZ-6 50-700 13

2) Using tool X2, raise and place window

glass (3) on tool X1-1 (5-mm spacer) and
stick it to the operator's cab.
a Match the lines of the match tapes
stuck in step 5.
a Stick the glass within 10 minutes after
applying the adhesive. CPW11623
a Before sticking the glass, check that
the primer is applied to the surface to
which the glass will be stuck.
9. Cure the stuck window glass for a certain time.

a Curing time before removing tool X1-1 (5-
CPW11622 mm spacer) (at temperature of 20C and
humidity of 60%): 10 hours
a Curing time before operating machine:
1 day
10. If the front glass and both front glasses are

replaced, seal them.
1) Stick masking tapes (14) along the parts to
a Check clearance ( k ) between the be sealed shown in the figure.
front side of the front glass and each a Stick the masking tapes to both inside
side and adjust it evenly. and outside of the operator's cab.
q Clearance ( k ) : 5 mm
CPW11628
CWW11626
3) After sticking window glass (3), press it

evenly.
a Press all over the window glass to the
degree that the window glass will be
stuck to the double-sided adhesive
tape. CWW11629
a Do not press the window glass too
strongly.
50-700 14 WA320, 320PZ-6

2) Fill the joint of the glasses with caulking

material (15).
a The expiration date of the following
caulking material is 4 months after the
date of manufacture. Do not use the
caulking material after its usable
period.
2 Caulking material:
SUNSTAR PENGUINE
SEAL NO. 2505
CPW11631
3) Remove the caulking material projected

from the joint with cardboard [8], etc.
CPW11632
4) Remove the masking tapes from the win-

dow glass.
11. Remove the primer and adhesive from the

operator's cab and window glass.
a Using white gasoline, wipe off the adhe-
sive before it is dried up.
a When cleaning the glass, do not make an
impact to it.
WA320, 320PZ-6 50-700 15

SEN04207-00 Disassembly and assembly of operator's seat assembly
Disassembly and assembly of operator's seat assembly 1
a The procedure for disassembling and assembling the operator's seat assembly [air-suspension (manu-
factured by ISRING HAUSEN is optional.)] is shown below.
A: Headrest D: Left-hand armrest

B: Back seat E: Suspension cover
C: Cushion seat F: Rails
Disassembly
1. Headrest
1) Referring to the figure, check the positions
of 2 clips (2) of headrest stay (1) on both
sides.
50-700 16 WA320, 320PZ-6

Disassembly and assembly of operator's seat assembly SEN04207-00
2) Apply force (b) to part (a) of each clip (2) 2. Back seat
in the direction of the arrow to turn the clip 1) Disconnect 3 air hoses (5) from the rear
and release it from part (d) of headrest left of back seat (4).
stay (1), and then pull out up headrest (3). a Before disconnecting the air hoses, check
their types.
2) Remove back seat hinge mounting bolt (6)

(M8 bolt).
a Pushing in both clips (2) simultaneously,

remove headrest (3).
3) Bring back seat (4) down forward.
WA320, 320PZ-6 50-700 17

4) Apply force (E) to the right side of back 3. Cushion seat

seat (4) in the direction of the arrow. 1) Push cushion adjuster lever (7) inward
5) Applying the force to back seat (4), pull its and slide cushion seat (8) to the front end.
right side up.
6) Slide back seat (4) sideway and remove it.
2) Push cushion slide stopper wire (9) down

with screwdriver [1], etc.
3) Keeping the state in 2), pull out cushion
seat (8) forward and remove it.
50-700 18 WA320, 320PZ-6

4. Armrest 4) Turn left-hand armrest (10) up by 180.

The procedure for disassembling left-hand a If the armrest is not turned, you can-
armrest (10) is shown below. not apply the tool to upper mounting
bolt (15B).
5) Remove plastic cap (14) and upper
mounting bolt (15B).
1) Remove plastic cap (12) from the armrest

hinge.
a Use a flat-head screwdriver, etc. to
remove the cap. 6) Remove left-hand armrest (10).
2) Loosen armrest hinge mounting bolt (13). a There are 2 position adjustment
washers (16) installed to each bolt
between the armrest and back seat.
Take care not to lose them.
3) Remove plastic cap (14), and then remove

lower mounting bolt (15A) (M8 bolt) of left-
hand armrest (10).
WA320, 320PZ-6 50-700 19

5. Suspension cover 4) Remove 4 mounting bolts (20), cushion

1) Remove right-hand hinge cover (17). rear fixing plate (21), 2 cushion rails (22),
2) Remove plastic plate (18) from the rear and 4 bushings (23).
with screwdriver [1], etc.
a Take care not to damage the plastic
plate by prying it off forcibly with a
screwdriver, etc.
5) Remove 3 metallic suspension cover clips

(24).
3) Remove 4 suspension cover fixing rings

(19).
50-700 20 WA320, 320PZ-6

6) Remove 6 plastic suspension cover clips 2) Slide rails (28) to the rear end.
(small) (25) and 2 plastic suspension 3) Remove 1 hexagon socket head bolt (29)
cover clips (large) (26). and 1 lock washer (30) from the front part
a Clips (small) (25): of each rail.
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
7) Remove suspension cover (27).
a If you remove the suspension cover
without performing the work in steps
5) and 6), the suspension cover may
be broken.
4) Slide rails (28) to the front end.

5) Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the rear part
of each rail, and then remove rails (28).
6. Rails
1) Turn over the seat assembly to set rails
(28) upside.
a Take care not to lose height adjust-

ment washers (31) between the rails
and suspension.
WA320, 320PZ-6 50-700 21

Assembly 2. Suspension cover

1. Rails 1) Set suspension cover (27) in position and
1) Put height adjustment washers (31) between install 6 plastic suspension cover clips
rails (28) and suspension, and then set rails (small) (25) and 2 plastic suspension
(28) in position. cover clips (large) (26).
a Clips (small):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large):
Front lower part; 2 places
2) Set rails (28) to the front end and install 1

lock washer (30) and 1 hexagon socket
head bolt (29) to each rail.
3 Hexagon socket head bolt:
21.4 27.6 Nm {2.18 2.82 kgm}
2) Install 3 metallic suspension cover clips

(24).
3) Set rails (28) to the rear end and install 1

lock washer (30) and 1 hexagon socket
head bolt (29) to each rail.
3 Hexagon socket head bolt:
21.4 27.6 Nm {2.18 2.82 kgm}
50-700 22 WA320, 320PZ-6

3) Set 4 bushings (23) and 2 cushion rails 3. Armrest

(22), and then install cushion rear fixing The procedure for assembling left-hand arm-
plate (21) and 4 mounting bolts (20). rest (10) is shown below.
3 Cushion rail mounting bolt:
21.4 27.6 Nm {2.18 2.82 kgm}
1) Install 2 position adjustment washers (16)

for each bolt and set left-hand armrest
4) Install 4 suspension cover fixing rings (10) in position.
(19).
2) Tighten lower mounting bolt (15A) lightly

5) Install plastic plate (18) to the rear. and turn armrest (10) by 180.
6) Install right-hand hinge cover (17). 3) Tighten upper mounting bolt (15B) lightly.
4) Tighten lower mounting bolt (15A) and
upper mounting bolt (15B) permanently.
3 Upper and lower armrest mounting
bolt:
21.4 27.6 Nm {2.18 2.82 kgm}
5) Install 2 plastic caps (14).
WA320, 320PZ-6 50-700 23

6) Tighten armrest hinge mounting bolt (13). 5. Back seat

a Tighten the bolt so that the arm will 1) Insert the left side of back seat (4), and
move smoothly. then lower and set the right side.
q Operating effort at armrest end:
49.0 78.4 N {5 8 kg}
7) Install plastic cap (12).
4. Cushion seat
1) Slide in the cushion seat from the front of
the fitting position.
a If cushion seat (8) is slid to the rear, it
is locked by cushion stopper wire (9).
2) Install back seat hinge mounting bolt (6).

3 Back seat hinge mounting bolt:
21.4 27.6 Nm {2.18 2.82 kgm}
50-700 24 WA320, 320PZ-6

3) Connect 3 air hoses (5) to the rear left of

back seat (4).
6. Headrest
1) Insert headrest (3) in back seat (4).
a Check that 2 clips (2) on both sides
are locked securely.
WA320, 320PZ-6 50-700 25

SEN04207-00 Removal and installation of air conditioner unit
Removal and installation of air 4. Disconnect wiper water hose (12) from the
conditioner unit 1
front outside of the cab.
Removal 5. Remove wiper blades (13).

rear frames.
k Disconnect the cable from the negative () CPW11631

the atmosphere. 6. Disconnect wiper water hose (14) from the
k If the refrigerant (R134a) gets inside inside of the cab.
Therefore, make sure to wear protec- 7. Disconnect wiper wiring harness connector
tive glasses when collecting or filling (15).
work must be conducted by a qualified 8. Remove wiper motor assembly (16).
person.
then drain the coolant. CPW11631
1. Recover the refrigerant (R134a). [*1]
2. Drain the coolant.

3. Remove the monitor panel, referring to the 9. Remove left duct (17) and right duct (18).
Removal and installation of monitor panel.
CPW11631
50-700 26 WA320, 320PZ-6

Removal and installation of air conditioner unit SEN04207-00
10. Disconnect right lower duct hose (19). 16. Remove right cover (30).
11. Remove 8 mounting bolts (20) and plate (21).
CPW11631
CPW11631
17. Disconnect heater hoses (32) and (33) and air

conditioner pipes (34) and (35) at the lower
12. Remove left cover (22). right of air conditioner unit (31).
a Plug the disconnected hoses and ports to
13. Disconnect the following wiring harness con- prevent foreign matter from entering them.
nectors. [*2]
q (23): CN-C50
q (24): CN-C49 18. Disconnect wiring harness connector (36).
q (25): CN-AL1
14. Remove air conditioner internal air filter case

(26).
CPW11631
CPW11631
19. Disconnect blower motor wiring harness con-

nector (37) from the lower left of the operator's
cab floor and pull out the wiring harness and
grommet (38) together above the floor.
15. Disconnect wiring harness connectors (28)
and fuse (29).
CPW11631
CPW11631
WA320, 320PZ-6 50-700 27

SEN04207-00 Removal and installation of air conditioner unit
20. Remove air conditioner assembly (31) upward. 3) Remove air conditioner external air duct
a Check that all the wiring and piping are (42) from the lower left of the floor.
disconnected.
CPW11631
CPW11631
4) Remove the 5 mounting bolts and blower

motor assembly (43).
a Remove the 5 mounting bolts at the
arrows (The ones marked with *
among them are used to fix the exter-
nal air filter case, too).
CPW11631
CPW11631
21. Blower motor assembly

1) Remove side cover (39) and front cover
(40) at the lower left of the operator's cab.
2) Remove air conditioner external air filter
case (41).
CPW11631 CPW11631
50-700 28 WA320, 320PZ-6

Removal and installation of air conditioner unit SEN04207-00
[*2]
a Do not remove the plugs installed when the
piping was disconnected to prevent entry of
foreign matter until just before connecting the
piping.
2 O-ring and threaded part:
CPW11631 Compressor oil for R134a (SANDEN: SP-
10 or equivalent)
3 Hose adapter mounting bolt (44):
8 12 Nm {0.8 1.2 kgm}
Installation CPW11631
removal.
[*1]
not enter them.
check that O-ring (70) is fitted to it. q Refilling with coolant
a Check O-ring (70) for a flaw and deterioration. Add coolant through the coolant filler to the
a When connecting each refrigerant pipe, apply specified level. Run the engine to circulate the
compressor oil for new refrigerant (R134a) coolant through the system. Then, check the
(DENSO: ND-OIL8 or ZEXEL ZXL100PG coolant level again.
5
(equivalent to PAG46)) to O-ring (70).
Total amount of coolant: 26.5 l
12 15 Nm {1.2 1.5 kgm}
20 25 Nm {2.0 2.5 kgm}
30 35 Nm {3.0 3.5 kgm}
CPW11631
q Charging with refrigerant (R134a)

Charge the air conditioner circuit with refriger-
ant (R134a).
WA320, 320PZ-6 50-700 29

SEN04207-00

2008 KOMATSU
All Rights Reserved
50-700 30
SEN04208-00
WA320-6
WA320PZ-6
WA320-6 70001 and up

800 Electrical system

Removal and installation of monitor panel ...................................................................................................... 2
Removal and installation of engine controller assembly ................................................................................. 4
Removal and installation of HST controller assembly..................................................................................... 5
Removal and installation of KOMTRAX terminal assembly ............................................................................ 6
WA320, 320PZ-6 50-800 1

SEN04208-00 Removal and installation of monitor panel
Removal and installation of 3. Remove 8 mounting bolts (1a) and panel cover
monitor panel 1
(1). [*1]
Removal
rear frames.
1. Pull out each switch from panel cover (1) on

the left side of the operator's seat and discon-
nect the following connectors.
q (2): CN-L10 4. Remove 2 pieces (9) and 1 piece (10) of the
q (3): CN-L11 monitor panel mounting bolts. [*2]
q (4): CN-L09
a The installed connectors and switches
depend on the specification.
2. Pull out each switch from panel cover (1) on

the right side of the operator's seat and discon-
nect the following connectors.
q (5): CN-L19
q (6): CN-L07
q (7): CN-L08
q (8): CN-L06
a The installed connectors and switches
depend on the specification.
50-800 2 WA320, 320PZ-6

Removal and installation of monitor panel SEN04208-00
5. Reverse monitor panel assembly (11) halfway

and disconnect the following connectors from
the rear side.
q (12):
q (13): CN-L30
q (14): CN-L28
q (15): CN-L27
q (16): CN-L26
q (17): CN-L25
q (18): CN-L29
q (19): CN-L24
a Take care not to strain the wiring since it is
short.
6. Remove monitor panel assembly (11).
Installation
removal.
[*1]
3 Panel cover mounting bolt (1a):
3.44 4.40 Nm {0.35 0.45 kgm}
[*2]
3 Monitor panel mounting bolts (9) and (10):
2.75 3.53 Nm {0.28 0.30 kgm}
7. Remove bracket (20) from monitor panel

assembly (11).
WA320, 320PZ-6 50-800 3

SEN04208-00 Removal and installation of engine controller assembly
Removal and installation of 4. Disconnect 5 mounting bolts (6) and engine

engine controller assembly 1
controller assembly (7). [*2]
a Take care not to drop the engine controller
Removal assembly or give it a shock.
rear frames.
1. Open and fix right engine side cover (1).

a Check that the cover is locked securely.
Installation
removal.
a Before installing the engine controller assem-
bly, remove foreign matter (water, dirt, etc.)
from its wiring harness connector.
[*1]
3 Wiring harness connector mounting bolt:
2. Remove 2 connector mounting bolts (2). [*1] 3 0.1 Nm {0.31 0.01 kgm}
a Width across flats of hexagonal socket of
mounting bolt: 4 mm [*2]
3 Engine controller assembly mounting bolt:
3. Disconnect connectors CN-EC2 (3), CN-EC1 24 4 Nm {2.45 0.4 kgm}
(4) and CN-EC3 (5).
50-800 4 WA320, 320PZ-6

Removal and installation of HST controller assembly SEN04208-00
Removal and installation of HST Installation

controller assembly 1
removal.
Removal a Before installing the HST controller assembly,
k Stop the machine on a level ground and set remove foreign matter (water, dirt, etc.) from its
the lock bar to the frame to fix the front and wiring harness connector.
rear frames.
1. Slide the operator's seat to the forward end.
2. Remove cover (1) from the rear of the opera-

tor's seat.
3. Disconnect wiring harness connector CN-HST

(2).
4. Remove HST controller (3).

a Take care not to drop the engine controller
assembly or give it a shock.
WA320, 320PZ-6 50-800 5

SEN04208-00 Removal and installation of KOMTRAX terminal assembly
Removal and installation of 4. Disconnect wiring harness connector CN-L80

KOMTRAX terminal assembly 1
(3) on the chassis from KOMTRAX terminal
assembly (2).
Removal a First, disconnect the wiring harness con-
k Stop the machine on a level ground and set nector on the chassis then the antenna
the lock bar to the frame to fix the front and cable connector because disconnecting
rear frames. the antenna cable connector before dis-
k Lower the work equipment to the ground, connecting the wiring harness connector
stop the engine, apply the parking brake, input disconnection of the antenna cable
and put chocks under the tires. into the KOMTRAX. [*1]
k Disconnect the cable from the negative () a To remove CN-L80 (3), loosen the hexa-
terminal of the battery. gon socket head screw at its center. [*2]
1. Open the right door of the operator's cab. 5. Disconnect antenna cable connectors (4) and
a Lock the door securely. (5) from KOMTRAX terminal assembly (2).
2. Remove right armrest outside cover (1) of the

operator's seat.
Installation
3. Remove KOMTRAX terminal assembly (2). q Carry out installation in the reverse order to
removal.
a Before installing the KOMTRAX terminal
assembly, remove foreign matter (water, dirt,
etc.) from its wiring harness connector.
[*1]
a First, connect the antenna cable connectors
then the wiring harness connector on the chas-
sis.
[*2]
3 Hexagon socket head screw at center of wir-
ing harness connector CN-L80 (3):
2.82 Nm {0.288 kgm}
50-800 6 WA320, 320PZ-6

Removal and installation of KOMTRAX terminal assembly SEN04208-00
WA320, 320PZ-6 50-800 7

SEN04208-00

2008 KOMATSU
All Rights Reserved
50-800 8
SEN04209-01
WA320-6
WA320PZ-6
WA320-6 70001 and up

90 Diagrams and drawings 1
100 Hydraulic diagrams and drawings

Automatic greasing circuit diagram................................................................................................................. 2
Hydraulic circuit diagram................................................................................................................................. 5
WA320, 320PZ-6 90-100 1

SEN04209-01 Automatic greasing circuit diagram
Automatic greasing circuit diagram 1
(If equipped)
90-100 2 WA320, 320PZ-6

Automatic greasing circuit diagram SEN04209-01
A: Automatic greasing pump assembly

B: Feeder 1
C: Feeder 2
D: Feeder 3
E: Feeder 4
Greasing parts
1. Bucket pin (left)
2. Bucket pin (right)
3. Lift arm pivot pin (left)
4. Lift arm pivot pin (right)
5. Bucket link pin (bucket side)
6. Bucket link pin (bell crank side)
7. Bell crank pin
8. Bucket cylinder head pin
9. Bucket cylinder bottom pin
10. Lift cylinder bottom pin (left)
11. Lift cylinder head pin (left)
12. Lift cylinder bottom pin (right)
13. Lift cylinder head pin (right)
14. Steering cylinder bottom pin (right)
15. Steering cylinder bottom pin (left)
16. Center hinge pin (upper)
17. Center hinge pin (lower)
18. Steering cylinder head pin (right)
19. Steering cylinder head pin (left)
20. Rear axle pivot pin (front side)
21. Rear axle pivot pin (rear side)
22. Rear axle pivot pin (rear side)
WA320, 320PZ-6 90-100 3

SEN04209-01 Automatic greasing circuit diagram
90-100 4 WA320, 320PZ-6

Hydraulic circuit diagram
Hydraulic circuit diagram WA320-6
1
WA320-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN04209-01
WA320, 320PZ-6
90-100 5
Hydraulic circuit diagram
Hydraulic circuit diagram WA320PZ-6
1
WA320PZ-6
SEN04209-01
WA320, 320PZ-6
90-100 7
SEN04209-01
WA320, 320PZ-6 90-100 9

SEN04209-01

2008 KOMATSU
All Rights Reserved
90-100 10
SEN04210-03
WA320-6
WA320PZ-6
WA320-6 70001 and up

90 Diagrams and drawings 1
200 Electrical diagrams and drawings

Electrical circuit diagram ................................................................................................................................. 3
Connector list and stereogram...................................................................................................................... 29
WA320, 320PZ-6 90-200 1

SEN04210-03
90-200 2 WA320, 320PZ-6

Common electrical circuit diagram (1/9)
Common electrical circuit diagram (1/9) Electrical circuit diagram 1
WA150-6, WA200-6, WA250-6, WA250PZ-6,
WA150-6, WA200-6, WA250-6, WA250PZ-6, WA320-6, WA320PZ-6
WA320-6, WA320PZ-6
SEN04210-03
WA320, 320PZ-6
90-200 3
Common electrical circuit diagram (2/9) Common electrical circuit diagram (2/9)
WA150-6, WA200-6, WA250-6, WA250PZ-6,
WA320-6, WA320PZ-6
SEN04210-03
WA320, 320PZ-6
90-200 5
WA150-6, WA200-6, WA250-6, WA250PZ-6,
WA320-6, WA320PZ-6
SEN04210-03
WA320, 320PZ-6
90-200 7
WA150-6, WA200-6, WA250-6, WA250PZ-6,
WA320-6, WA320PZ-6
SEN04210-03
WA320, 320PZ-6
90-200 9
WA200-6, WA250-6, WA250PZ-6
WA200-6, WA250-6, WA250PZ-6
SEN04210-03
WA320, 320PZ-6
90-200 11
WA150-6, WA200-6, WA250-6, WA250PZ-6,
WA320-6, WA320PZ-6
SEN04210-03
WA320, 320PZ-6
90-200 13
WA200-6, WA250-6, WA250PZ-6
WA200-6, WA250-6, WA250PZ-6
SEN04210-03
WA320, 320PZ-6
90-200 15
WA150-6, WA200-6, WA250-6, WA250PZ-6,
WA320-6, WA320PZ-6
SEN04210-03
WA320, 320PZ-6
90-200 17
WA150-6, WA200-6, WA250-6, WA250PZ-6,
WA320-6, WA320PZ-6
SEN04210-03
WA320, 320PZ-6
90-200 19
Specific electrical circuit diagram (1/4) Specific electrical circuit diagram (1/4)
WA320-6, WA320PZ-6
WA320-6, WA320PZ-6
SEN04210-03
WA320, 320PZ-6
90-200 21
WA320-6, WA320PZ-6
WA320-6, WA320PZ-6
SEN04210-03
WA320, 320PZ-6
90-200 23
WA320-6, WA320PZ-6
WA320-6, WA320PZ-6
SEN04210-03
WA320, 320PZ-6
90-200 25
WA320PZ-6
WA320PZ-6
SEN04210-03
WA320, 320PZ-6
90-200 27
Connector list and stereogram
Connector list and stereogram WA320-6, WA320PZ-6 WA320-6, WA320PZ-6
Connector No. Model Number Component name Address of Connector No. Model Number Component name Address of Connector No. Model Number Component name Address of
of pins stereogram of pins stereogram of pins stereogram
2 Water in fuel sensor F07A DT-T 2 Diode F-1 L70 SWP 8 Speed range select resistor O-9
AL1 DT-T 6 Intermediate connector T-1 F10 Terminal 1 GND (front frame) E-1 L71 DT-T 4 Intermediate connector W-2
AMBAIR
PRESURE 3 Ambient pressure sensor AC-3 F11 DT-T 2 Steering pump pressure switch H-1 L79 5 KOMTRAX engine cut relay P-6
B01 DT-T 2 Rear work lamp RH K-9 F12 DT-T 2 Emergency steering pressure switch H-1 L80 DRC key A 40 KOMTRAX controller T-8
B02 DT-T 2 Rear work lamp LH M-8 F14 DT-T 2 Brake oil temperature switch A-1 L100 Terminal 1 GND (floor) Y-3
B03 DT-T 2 Back up alarm M-7 F15 DT-T 3 Lift arm angle sensor (for load meter) A-4 L101 6 FR press select relay AB-7
B05 DT-T 2 Coolant level sensor K-9 F16 DT-T 3 Lift arm bottom sensor (for load meter) A-2 L102 5 VIS power hold relay Z-8
B05 Terminal 1 GND (license lamp) M-7 F17 DT-T 3 Lift arm rod sensor (for load meter) E-1 L103 5 Motor 2 solenoid relay Z-8
B06 08027 2 (R) Window sealed washer motor I-9 FL1 DT-T 12 Intermediate connector D-7, V-1 L104 5 Fan reverse solenoid relay Z-8
B07 08027 2 (F) Window sealed washer motor I-9 FL2 DT-T 6 Intermediate connector D-8, V-2 L105 5 Electrical parking brake relay AA-7
B08 DT-T 2 Diode K-9 FL3 DT-T 4 Intermediate connector I-1, W-2 L106 5 Neutral safety relay AA-7
B09 DT-T 2 Diode J-9 FL4 DT-T 6 Intermediate connector I-1, V-2 L107 5 Engine controller cut 1 relay Z-7
BL1 DT-T 6 Intermediate connector X-2 FLC DT-T 3 Front combination lamp RH B-6 L108 5 Engine controller cut 2 relay Z-8
BOOST PRESS &
INT 4 Boost pressure sensor AF-4 FLC1 DT-T 3 Front combination lamp LH H-1 L109 5 Back alarm/lamp 1 relay AB-7
BR1 DT-T 4 Intermediate connector L-8 FLH DT-T 3 Head lamp RH B-6 L110 5 ECSS relay AB-7
C04 DT 2 Front work lamp (RH) 24V/70W E-8 FLH DT-T 3 Head lamp LH G-1 L111 5 HST solenoid safety relay AB-8
C05 DT 2 Front work lamp (LH) 24V/70W H-9 FS1 15 Fuse box V-9 L112 5 Air clearner clog relay AB-8
C07 YAZAKI 2 Room lamp H-9 FS2 15 Fuse box V-9 L113 5 Boom kick out relay AB-9
7123-2228
YAZAKI FUEL RAIL
C08 -08056 1 Door switch (LH) (room lamp) H-9 PRESS 3 Common rail pressure sensor AG-5 L114 5 Bucket leveler relay AA-9
C09 YAZAKI 1 Door switch (RH) (room lamp) E-8 HEAD L DT-T 6 Intermediate connector G-1 L115 5 Detent active relay AA-9
-08056
C10 Terminal 1 GND to radio body F-9 HEAD R DT-T 6 Intermediate connector A-5 L116 5 Horn relay AA-9
C11 YAZAKI PA 9 AM/FM radio F-9 HST DRC 40 HST controller Z-6 L117 5 Small lamp relay LH AA-6
C12 M 2 Speaker LH I-9 INJ. CYL. 1 & 2 4 Injector #1 & #2 AE-4 L118 5 Small lamp relay RH AA-5
C13 M 2 Speaker RH G-9 INJ. CYL. 3 & 4 4 Injector #3 & #4 AF-5 L119 5 Head lamp relay RH AA-5
C14 198-Z11-2650 2 Lighter D-7 INJ. CYL. 5 & 6 4 Injector #5 & #6 AG-5 L120 5 Head lamp relay LH AA-5
C15 DT 3 Intermediate connector J01 M6409-0075 20 Joint connector R-6 L121 5 Stop lamp relay Z-5
C16 DT 2 Warning lamp (beacon) J02 M6409-0255 20 Joint connector R-6 L122 5 Front work lamp relay AA-4
C17 SWP 6 Warning lamp (beacon) switch (If equipped) J03 M6409-0071 20 Joint connector V-1 L123 5 Rear work lamp relay AB-4
C18 SWP 6 Warning lamp (pat. light) switch (If equipped) J04 M6409-0075 20 Joint connector Y-9 L124 6 Hazard/turn signal relay AB-4
C18 Terminal 1 GND (cabin) E-8 J05 M6409-0072 20 Joint connector Y-9 L125 5 Hazard relay AB-4
C19 SWP 6 Rear glass heater switch G-9 J06 M6409-0071 20 Joint connector Y-9 L126 5 Back alarm/lamp 2 relay AB-6
C20 5 Relay for rear glass heater G-9 J07 M6409-0072 20 Joint connector R-8 L151 5 Front work lamp (yellow) relay (If equipped)
C21 YAZAKI 1 Rear glass heater G-9 J08 M6409-0075 20 Joint connector Q-4 L152 5 Warning lamp (beacon) relay
7116-2270
YAZAKI
C22 7116-2270 1 Rear glass heater J-9 J09 M6440-0128 20 Joint connector Y-9 L153 5 Warning lamp (pat.light) relay (If equipped)
C23 DT 4 Intermediate connector E-8 J10 M6409-0255 20 Joint connector Y-9 L154 6 Warning lamp (pat.light) switch relay (If equipped)
C47 22 Manual A/C control amp F-9 J11 M6440-0135 20 Joint connector Z-8 LR1 #8 1 Intermediate connector N-3, AB-2
C48 14 Manual A/C control amp F-9 J12 M6409-0075 20 Joint connector Z-8 LR2 DT-T 12 Intermediate connector N-3, AB-2
C49 DT-T 12 Intermediate connector F-1 J13 M6409-0128 20 Joint connector R-6 LR3 DT-T 6 Intermediate connector N-3, AB-1
C50 DT-T 12 Intermediate connector F-1 J14 M6409-0075 20 Joint connector Z-8 LR4 #8 1 Intermediate connector N-2, AB-1
C140 DRC 40 Tachograph controller J15 M6440-0128 20 Joint connector O-4 LR6 #8 1 Intermediate connector M-3, X-1
C142 YAZAKI 17 Tachograph J16 M6409-0128 20 Joint connector Z-7 LR7 DT-T 12 Intermediate connector M-3, X-1
7119-3170
CAM SENSOR 3 G sensor AD-1 J17 M6409-0073 20 Joint connector Z-7 LR10 DT-T 3 Intermediate connector N-3, AB-2
CAN1 DT-T 3 CAN resistor AG-1 L02 DT-T 4 Starting switch R-9 LR11 DTP 4 Intermediate connector M-3, X-1
CAN2 DT-T 3 CAN resistor S-1 L03 DT-T 4 Speed range selector switch R-8 LR12 #8 1 Intermediate connector N-3, AB-1
CHK0 X 1 KOMTRAX inspection connector P-6 L04 SWP 8 Combination lamp switch T-1 LT1 DT-T 12 Intermediate connector M-3, X-2
CHK1 X 1 KOMTRAX inspection connector P-6 L05 S 10 Wiper switch (front, rear) S-1 LT2 DT-T 6 Intermediate connector M-3, X-2
CL1 SWP 6 Intermediate connector C-6, O-2 L06 SWP 6 Hazard switch R-6 MF1 DTM 12 Multi function lever switch
OIL PRESURE
CL2 SWP 8 Intermediate connector C-7, O-3 L07 SWP 6 Front work lamp switch Q-5 SWITCH Engine pressure switch (low) AH-2
CL31 DT-T 2 Diode L08 SWP 6 Rear work lamp switch R-6 PD1 DT-T 6 Throttle pedal switch O-2
CL32 DT-T 2 Diode L09 SWP 6 ECSS switch T-1 PD2 DT-T 2 Throttle pedal switch O-2
COOLANT TEMP 2 Engine coolant temperature sensor AD-4 L10 SWP 6 Monitor 1 switch U-1 R00 Terminal 1 GND M-8
CP3 PUMP 2 IMA fuel pump actuator AH-4 L11 SWP 6 Monitor 2 switch T-1 R01 Terminal 1 Battery relay A-8
REGULATOR
CRANK SENSOR 3 Ne sensor AD-1 L13 DT-T 2 Horn switch T-1 R02 Terminal 1 Slow blow fuse A-9
D01 SWP 8 Diode O-8 L15 DT-T 4 FNR switch S-2 R03 Terminal 1 Slow blow fuse B-9
D02 SWP 8 Diode O-8 L16 SWP 6 Loadmeter A/B (If equipped) U-1 R04 Terminal 1 Battery relay A-9
D03 SWP 8 Diode O-8 L17 SWP 6 Loadmeter total (If equipped) V-1 R05 Terminal 1 Slow blow fuse B-9
D07 DT-T 2 Diode O-7 L24 AMP 070 20 Monitor panel R-2 R05A Terminal 1 Slow blow fuse B-9
D08 DT-T 2 Diode O-7 L25 AMP 070 18 Monitor panel R-2 R06 Terminal 1 Slow blow fuse B-9
D09 DT-T 2 Diode O-7 L26 AMP 070 12 Monitor panel R-2 R11 Terminal 1 Slow blow fuse B-9
D10 DT-T 2 Diode O-7 L27 AMP 070 18 Monitor panel Q-3 R15 Terminal 1 Battery relay B-7
D21 DT-T 2 Diode K-2 L28 AMP 070 12 Monitor panel Q-4 R16 Terminal 1 Battery relay A-7
D22 DT-T 2 Diode J-1 L29 AMP 070 12 Monitor panel T-7 R20 Terminal 1 GND (rear frame) J-1
E01 DT-T 2 Starting motor safety relay AF-5 L30 AMP 070 14 Monitor panel S-7 R21 DT-T 2 Fuel level sensor M-5
SUMITOMO
E02 6189-0442 3 Alternator M-6 L34 DT-T 2 Stop lamp switch W-2 R22 DT-T 6 Rear combination lamp LH M-6
E03 Terminal 1 Alternator terminal B M-7 L35 DT 2 PPC valve with electrical detent Q-9 R23 DT-T 6 Rear combination lamp RH K-9
E05 Terminal 1 Heater relay terminal B C-7 L36 DT 2 PPC valve with electrical detent R-6 R24 DT-T 2 License lamp (If equipped) L-9
E06 Terminal 1 Heater relay C-9 L37 DT 2 PPC valve with electrical detent R-6 R26 Terminal 1 GND (rear frame) G-1
E06A DT-T 2 Diode K-2 L38 DT-T 2 UN switch +24 V (If equipped) Z-4 R29 DT-T 2 Oil fan EPC solenoid L-9
E07A Terminal 1 Heater relay terminal A AF-5 L39 DT-T 2 Key on +24 V (If equipped) Z-4 R59 DT-T 2 Fan reverse solenoid M-8
E07B 1 Electrical intake air heater AD-9 L45 DT-T 6 Auto lubrication AB-2 R90 Terminal 1 Heater relay terminal E L-4
E10 DT-T 2 Freon compressor magnet clutch AH-1 L46 M 2 Buzzer W-9 SV DT-T 12 Service connector Y-8
E14 Terminal 1 GND (engine controller) AG-1 L47 DT 2 Parking brake indicator switch Y-3 T01 DT-T 4 HST pump solenoid AC-4
E15 Terminal 1 GND (engine controller) AH-1 L48 08027 6 Wiper timer X-2 T01A 2 Diode AD-4
E19 Terminal 1 Starting motor safety relay AG-6 L49 08027 4 Flasher AA-3 T01B 2 Diode AD-4
E20 Terminal 1 Starting motor safety relay AG-6 L50 DT-T 12 Intermediate connector Z-6 T05 DT-T 2 Clutch control EPC solenoid N-2, AN-7
E21 Terminal 1 Starting motor terminal C AC-7 L52 M 4 Rear wiper motor X-9 T06 DT-T 2 HST motor 1 EPC solenoid L-1, AK-2
E26 DT-T 2 Engine oil level sensor AF-5 L53 DT 2 Parking brake remind switch Z-5 T07 DT-T 4 HST motor 2 solenoid & motor 2 overrun solenoid L-2, AJ-7
E30 Terminal 1 Starting motor terminal B AE-4 L54 DT-T 3 Variable shift control switch T-8 T09 DT-T 4 Speed sensor L-2, AL-8
E33 DT-T 2 Dust indicator J-9 L55 DT 2 Air suspension seat Z-5 T10 DT-T 2 HST oil temperature sensor L-2, AK-8
E41 DT-T 2 Intermediate connector AF-1 L57 M 6 Front wiper motor Q-3 T11 DT-T 3 HST oil pressure sensor M-1, AL-3
E42 DT-T 2 Intermediate connector AH-2 L58 M 2 12V option converter output Z-4 T12 DT-T 2 Brake accumurator pressure switch I-1
EC1 DRC 60 Engine controller module AE-1 L59 DT-T 4 Bucket lever LDM cancel switch (If equipped) Q-6 T13 1 HST filter clogging sensor M-1
EC2 DRC 50 Engine controller module AD-2 L60 DT-T 6 Intermediate connector Z-4 T14 Terminal 1 GND M-1
EC3 DTP 4 Engine controller module AF-1 L61 DT-T 4 Boom lever TCS cancel switch Q-6 T15 DT-T 2 Parking brake solenoid L-2, AL-8
ER1 DT-T 12 Intermediate connector D-8, AE-5 L62 DT-T 4 Intermediate connector Q-6 T15A DT-T 2 Diode N-1
ER2 DT-T 12 Intermediate connector D-8, AE-5 L63 SWP 6 FNR active switch Q-9 T18 DT-T 2 Parking brake pressure switch (for monitor indicator) N-2, AN-7
ER3 DT-T 2 Intermediate connector D-8, AE-5 L64 SWP 6 Traction switch Q-9 T31 DT-T 2 Diode
F01 08160-70001 2 Horn (high) C-1 L65 SWP 6 Work lamp (yellow) (If equipped) R-6 T32 DT-T 2 Diode
F02 08160-70001 2 Horn (low) D-1 L66 X 1 Intermediate connector O-3 TEL DT-T 12 Intermediate connector P-6
F03 DT-T 3 Bucket positioner proximity switch A-3 L67 DT-T 12 Intermediate connector W-9 TOOL PORT 3 CAN resistor AD-2
F04 DT-T 3 Lift arm positioner proximity switch A-4 L68 DT-T 2 Resistor O-7 Z01 DT-T 2 Diode
F07 DT-T 2 ECSS solenoid valve F-1 L69 SWP 6 Auto reversible fan switch Q-9 Z02 DT-T 2 Diode
SEN04210-03
WA320, 320PZ-6
90-200 29
SEN04210-03
WA320, 320PZ-6 90-200 31

SEN04210-03

2009 KOMATSU
All Rights Reserved
90-200 32

SM Wa320-6 70001-Up Sen04162-06

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SM Wa320-6 70001-Up Sen04162-06

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SEN04162-06

WHEEL LOADER WA320 -6

WHEEL LOADER 1SHOP MANUAL

Machine model Serial number

WA320-6 70001 and up

00 Index and foreword 00

WA320, 320PZ-6 00-100 1

Composition of shop manual 1

Section Title Form Number

00 Index and foreword .................................................................................................................... SEN04163-06

01 Specification ............................................................................................................................... SEN04164-01

10 Structure, function and maintenance standard........................................................................... SEN04165-03

20 Standard value table................................................................................................................... SEN04166-00

30 Testing and adjusting ................................................................................................................. SEN04167-03

00-100 2 WA320, 320PZ-6

350 Troubleshooting by failure code (Display of code), Part 5..................................................SEN04194-01

50 Disassembly and assembly ........................................................................................................SEN04169-03

90 Diagrams and drawings ..............................................................................................................SEN04170-03

WA320, 320PZ-6 00-100 3

00 Index and foreword

10 Structure, function and maintenance standard

00-100 4 WA320, 320PZ-6

400 Brake system SEN04177-00

20 Standard value table

WA320, 320PZ-6 00-100 5

30 Testing and adjusting

00-100 6 WA320, 320PZ-6

130 Testing and adjusting, Part 3 SEN04187-01

WA320, 320PZ-6 00-100 7

Failure code [CA342] Calibration code inconsistency................................................................................... 48

00-100 8 WA320, 320PZ-6

Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short.......................................... 20

WA320, 320PZ-6 00-100 9

00-100 10 WA320, 320PZ-6

50 Disassembly and assembly

WA320, 320PZ-6 00-100 11

90 Diagrams and drawings

00-100 12 WA320, 320PZ-6

WA320, 320PZ-6 00-100 13

WA320-6, WA320PZ-6 Wheel loader

WHEEL LOADER 1SHOP MANUAL

Machine model Serial number

WA320-6 70001 and up

00 Index and foreword 00

200 Foreword and general information

WA320, 320PZ-6 00-200 1

Safety notice (Rev. 2008/08)1

1. General precautions 7) If welding repairs are needed, always

00-200 2 WA320, 320PZ-6

2. Preparations for work 6) When removing a cover which is under

WA320, 320PZ-6 00-200 3

4. Precautions for sling work and making

00-200 4 WA320, 320PZ-6

WA320, 320PZ-6 00-200 5

00-200 6 WA320, 320PZ-6

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution