WA 320-6 Shop Manual

SEN03911-02
WHEEL LOADER
-6
WA320
WA320PZ -6
SERIAL NUMBERS
WA320- 70001
WA320PZ-70001
and up
SEN03920-02
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
00 Index and foreword
00
100 Index
Composition of shop manual .......................................................................................................................... 2
Table of contents............................................................................................................................................. 4
WA320, 320PZ-6 (KA SPEC.)
00-100
SEN03920-02
100 Index
Composition of shop manual
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 accordingly.
Section Title
Form Number
Shop Manual, contents binder, binder label and tabs ..................................................................... SEN03911-02
00 Index and foreword .................................................................................................................... SEN03912-02
100 Index .................................................................................................................................. SEN03920-02 q
200 Foreword and general information ..................................................................................... SEN03921-01
01 Specification ............................................................................................................................... SEN03913-01
100 Specification and technical data......................................................................................... SEN03922-01
10 Structure, function and maintenance standard........................................................................... SEN03914-02
100 Engine and cooling system ................................................................................................ SEN03923-01
200 Power train......................................................................................................................... SEN03924-01
300 Steering system ................................................................................................................. SEN03925-01
400 Brake system ..................................................................................................................... SEN03926-00
500 Undercarriage and frame ................................................................................................... SEN03927-00
600 Hydraulic system................................................................................................................ SEN03928-00
700 Work equipment................................................................................................................. SEN03929-01
800 Cab and its attachments .................................................................................................... SEN03930-00
910 Electrical system, Part 1 .................................................................................................... SEN03931-01
920 Electrical system, Part 2 .................................................................................................... SEN03932-02 q
20 Standard value table................................................................................................................... SEN03915-00
100 Standard service value table.............................................................................................. SEN03933-00
30 Testing and adjusting ................................................................................................................. SEN03916-02
110 Testing and adjusting, Part 1.............................................................................................. SEN03934-02 q
120 Testing and adjusting, Part 2.............................................................................................. SEN03935-02 q
130 Testing and adjusting, Part 3.............................................................................................. SEN03936-01
40 Troubleshooting.......................................................................................................................... SEN03917-02
100 Failure code table and fuse locations ................................................................................ SEN03937-01
200 General information on troubleshooting............................................................................. SEN03938-02 q
310 Troubleshooting by failure code (Display of code), Part 1 ................................................. SEN03939-00
00-100
100 Index
350
360
370
400
500
600
SEN03920-02
Troubleshooting by failure code (Display of code), Part 5..................................................SEN03943-01

Troubleshooting of electrical system (E-mode) ..................................................................SEN03946-01
Troubleshooting of hydraulic and mechanical system (H-mode)........................................SEN03947-01
Troubleshooting of engine (S-mode) ..................................................................................SEN03948-01
50 Disassembly and assembly ........................................................................................................SEN03918-02

100 General information on disassembly and assembly...........................................................SEN03949-01
200 Engine and cooling system ................................................................................................SEN03950-02 q
310 Power train, Part 1..............................................................................................................SEN03951-00
320 Power train, Part 2..............................................................................................................SEN03952-00
400 Undercarriage and frame ...................................................................................................SEN03953-00
500 Hydraulic system ................................................................................................................SEN03954-00
600 Work equipment .................................................................................................................SEN03955-00
700 Cab and its attachments.....................................................................................................SEN03956-00
800 Electrical system ................................................................................................................SEN03957-00
90 Diagrams and drawings..............................................................................................................SEN03919-01
100 Hydraulic diagrams and drawings ......................................................................................SEN03958-01
200 Electrical diagrams and drawings.......................................................................................SEN03959-01
00-100
SEN03920-02
Table of contents
100 Index
Table of contents

100 Index
SEN03920-02
Composition of shop manual.........................................................................................................................
2
Table of contents ...........................................................................................................................................
4
200 Foreword and general information
SEN03921-01
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
SEN03922-01
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
SEN03923-01
Engine mount and transfer mount.................................................................................................................
2
Damper .........................................................................................................................................................
3
Cooling system..............................................................................................................................................
4
Cooling system hydraulic piping diagram......................................................................................................
5
Cooling fan motor..........................................................................................................................................
7
200 Power train
SEN03924-01
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
SEN03925-01
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
100 Index
Table of contents
SEN03920-02
400 Brake system

SEN03926-00
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
SEN03927-00
Axle mount and center hinge pin ................................................................................................................... 2
Tires............................................................................................................................................................... 7
600 Hydraulic system
SEN03928-00
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
SEN03929-01
Work equipment linkage ................................................................................................................................ 2
Bucket............................................................................................................................................................ 6
Bucket positioner and boom kick-out............................................................................................................. 10
Work equipment cylinder ............................................................................................................................... 22
800 Cab and its attachments
SEN03930-00
Cab ................................................................................................................................................................ 3
Air conditioner................................................................................................................................................ 4
910 Electrical system, Part 1
SEN03931-01
Machine monitor system................................................................................................................................ 2
Machine monitor ............................................................................................................................................ 6
SEN03932-02
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
Multi-function knob ........................................................................................................................................ 33
Max. traction switch ....................................................................................................................................... 34
Sensor ........................................................................................................................................................... 35
20 Standard value table
100 Standard service value table
SEN03933-00
Standard service value table for engine ........................................................................................................ 2
Standard service value table for chassis ....................................................................................................... 3
00-100
SEN03920-02
100 Index
Table of contents
30 Testing and adjusting

110 Testing and adjusting, Part 1
SEN03934-02
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
SEN03935-02
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
SEN03936-01
Adjusting machine monitor............................................................................................................................
2
00-100
100 Index
Table of contents
SEN03920-02
Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor ............................ 3
Special functions of machine monitor (EMMS).............................................................................................. 5
Pm clinic inspection chart .............................................................................................................................. 60
40 Troubleshooting
100 Failure code table and fuse locations
SEN03937-01
Failure codes table ........................................................................................................................................ 2
Fuse locations ............................................................................................................................................... 8
200 General information on troubleshooting
SEN03938-02
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
SEN03939-00
Failure code [2G40ZG] Brake: Oil pressure reduction .................................................................................. 2
Failure code [6091NX] HST filter: Clogging................................................................................................... 4
Failure code [989FN1] Travel speed: Overrun alarm .................................................................................... 6
Failure code [AA1ANX] Air cleaner: Clogging ............................................................................................... 8
Failure code [AB00L6] Alternator R system: Hot short.................................................................................. 10
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage ................... 12
Failure code [B@BAZG] Engine: Oil pressure reduction............................................................................... 14
Failure code [B@BAZK] Engine oil: Low level............................................................................................... 15
Failure code [B@BCNS] Engine: Overheat................................................................................................... 16
Failure code [B@BCZK] Engine: Low coolant level ...................................................................................... 18
Failure code [B@C6NS] Front brake: High oil temperature .......................................................................... 20
Failure code [B@CRNS] HST: High oil temperature ..................................................................................... 21
SEN03940-00
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
Failure code [CA342] Calibration code inconsistency ................................................................................... 48
Failure code [CA351] Injectors drive circuit error .......................................................................................... 50
00-100
SEN03920-02
100 Index
Table of contents
Failure code [CA352] Sensor power supply 1 low error................................................................................ 52

Failure code [CA386] Sensor power supply 1 high error .............................................................................. 54
SEN03941-01
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
SEN03942-01
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
SEN03943-01
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
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short ......................................... 20
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault ................................. 22
00-100
100 Index
Table of contents
SEN03920-02
Failure code [DDD7KY] Travel speed control dial signal: Hot short .............................................................. 24
Failure code [DDE5MA] Emergency steering operation switch: Disconnection ............................................ 26
Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short............................................... 28
Failure code [DDK3KB] Directional selector switch: Ground fault ................................................................. 30
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault................................................................... 32
Failure code [DDK6KY] FNR lever: Hot short................................................................................................ 36
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) ................................ 38
SEN03944-01
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
SEN03945-00
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)
SEN03946-01
E-1 Engine does not start .............................................................................................................................. 4
E-2 Preheater does not operate normally...................................................................................................... 12
E-3 Travel speed is low or high ..................................................................................................................... 16
E-4 ECSS does not operate .......................................................................................................................... 22
E-5 ECSS keeps operating............................................................................................................................ 25
E-6 Defective boom kick-out function and cancellation ................................................................................. 28
E-7 Defective bucket positioner function and cancellation ............................................................................ 32
E-8 Defective lift arm FLOATING holding function and cancellation ............................................................. 36
E-9 Travel direction selection system does not function................................................................................ 40
E-10 Fan does not reverse ............................................................................................................................ 44
E-11 Fan keeps rotating in reverse................................................................................................................ 48
E-12 Wiper does not operate......................................................................................................................... 50
E-13 Windshield washer does not operate.................................................................................................... 54
E-14 Headlamp, clearance lamp and tail lamp do not light up or go off ........................................................ 58
E-15 Working lamp does not light up or go off............................................................................................... 66
00-100
SEN03920-02
100 Index
Table of contents
E-16 Turn signal lamp and hazard lamp do not light up or go off.................................................................. 72
E-17 Brake lamp does not light or it keeps lighting up .................................................................................. 78
E-18 Backup lamp does not light or it keeps lighting up ............................................................................... 80
E-19 Backup alarm does not sound or it keeps sounding............................................................................. 83
E-20 Horn does not sound or it keeps sounding ........................................................................................... 86
E-21 Alarm buzzer does not sound or it keeps sounding.............................................................................. 88
E-22 Air conditioner does not operate or stop............................................................................................... 90
E-23 The KOMTRAX system does not work properly................................................................................... 94
500 Troubleshooting of hydraulic and mechanical system (H-mode)
SEN03947-01
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)
SEN03948-01
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
100 Index
Table of contents
SEN03920-02
50 Disassembly and assembly

100 General information on disassembly and assembly
SEN03949-01
How to read this manual................................................................................................................................ 2
How to read this manual................................................................................................................................ 2
Special tool list............................................................................................................................................... 7
Sketches of special tools ............................................................................................................................... 11
SEN03950-02
Removal and installation of fuel supply pump assembly ............................................................................... 2
Removal and installation of fuel injector assembly ........................................................................................ 4
Removal and installation of cylinder head assembly ..................................................................................... 12
Removal and installation of engine hood assembly ...................................................................................... 24
Removal and installation of radiator .............................................................................................................. 27
Removal and installation of air aftercooler..................................................................................................... 30
Removal and installation of hydraulic oil cooler assembly ............................................................................ 32
Removal and installation of engine assembly ............................................................................................... 34
Removal and installation of engine front oil seal assembly ........................................................................... 40
Removal and installation of engine rear oil seal assembly ............................................................................ 43
Removal and installation of cooling fan and fan motor assembly.................................................................. 46
Removal and installation of fuel tank assembly............................................................................................. 49
310 Power train, Part 1
SEN03951-00
Removal and installation of transfer .............................................................................................................. 2
Disassembly and assembly of transfer assembly.......................................................................................... 5
Removal and installation of parking brake assembly..................................................................................... 24
Disassembly and assembly of parking brake assembly ................................................................................ 25
SEN03952-00
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
SEN03953-00
Removal and installation of center hinge pin................................................................................................. 2
Removal and installation of counterweight .................................................................................................... 12
SEN03954-00
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
SEN03955-00
Removal and installation of work equipment assembly ................................................................................. 2
SEN03956-00
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
SEN03957-00
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
00-100
11
SEN03920-02
100 Index
Table of contents
90 Diagrams and drawings

100 Hydraulic diagrams and drawings
SEN03958-01
Automatic greasing circuit diagram ...............................................................................................................
2
Hydraulic circuit diagram...............................................................................................................................
5
200 Electrical diagrams and drawings
SEN03959-01
Electrical circuit diagram ...............................................................................................................................
3
Connector list and stereogram ...................................................................................................................... 29
00-100
12
100 Index
Table of contents
SEN03920-02
00-100
13
SEN03920-02
WA320-6, WA320PZ-6 (KA SPEC.) Wheel loader

Form No. SEN03920-02
2009 KOMATSU
All Rights Reserved
Printed in Japan 07-09
00-100
14
SEN03921-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
00

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
00-200

Safety notice
SEN03921-01
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 situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1.
General precautions
k Mistakes in operation are extremely
dangerous. Read the Operation and
Maintenance Manual carefully before
operating the machine. In addition,
read this manual and understand its
contents before starting the work.
1) Before carrying out any greasing or
repairs, read all the safety labels stuck to
the machine. For the locations of the
safety labels and detailed explanation of
precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always
keep the tools and parts in their correct
places. Always keep the work area clean
and make sure that there is no dirt, water,
or oil on the floor. Smoke only in the areas
provided for smoking. Never smoke while
working.
3) When carrying out any operation, always
wear safety shoes and helmet. Do not
wear loose work clothes, or clothes with
buttons missing.
q
Always wear safety glasses when hitting parts with a hammer.
q
Always wear safety glasses when
grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or
more workers, always agree on the operating procedure before starting. Always
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, forklift, service car, etc.
00-200
7)
8)
9)
If welding repairs are needed, always

have a trained and experienced welder
carry out the work. When carrying out
weld in g wo rk , al way s wear wel din g
gloves, apron, shielding goggles, cap and
other clothes suited for welding work.
Before starting work, warm up your body
thoroughly to start work under good condition.
Avoid continuing work for long hours and
take rests at proper intervals to keep your
body in good condition. Take rests in
specified safe places.
Safety points
1 Good arrangement
2 Correct work clothes
3 Following work standard
4 Making and checking signs
5
Prohibition of operation and handling by

unlicensed workers
6 Safety check before starting work

7
Wearing protective goggles

(for cleaning or grinding work)
Wearing shielding goggles and protectors

(for welding work)
9 Good physical condition and preparation

10
Precautions against work which you are

not used to or you are used to too much

Safety notice
2.
3.
SEN03921-01
Preparations for work

1) Before adding oil or making any repairs,
park the machine on a hard and level
ground, and apply the parking brake and
block the wheels or tracks to prevent the
machine from moving.
2) Before starting work, lower the work
equipment (blade, ripper, bucket, etc.) to
the ground. If this is not possible, insert
the lock pin or use blocks to prevent the
work equipment from falling. In addition,
be sure to lock all the control levers and
hang warning signs on them.
3) When disassembling or assembling, support the machine with blocks, jacks, or
stands before starting work.
4) Remove all mud and oil from the steps or
other places used to get on and off the
machine. Always use the handrails, ladders or steps when getting on or off the
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
machine. If it is impossible to use the
handrails, ladders or steps, use a stand to
provide safe footing.
6)
Precautions during work

1) Before disconnecting or removing components of the oil, water, or air circuits, first
release the pressure completely from the
circuit. When removing the oil filler cap, a
drain plug, or an oil pressure pickup plug,
loosen it slowly to prevent the oil from
spurting out.
2) The coolant and oil in the circuits are hot
when the engine is stopped, so be careful
not to get scalded. Wait for the oil and
coolant to cool before carrying out any
work on the oil or water circuits.
3) Before starting work, stop the engine.
When working on or around a rotating
part, in particular, stop the engine. When
checking the machine without stopping
the engine (measuring oil pressure,
revolving speed, temperature, etc.), take
extreme care not to get rolled or caught in
rotating parts or moving parts.
4) Before starting work, remove the leads
from the battery. Always remove the lead
from the negative () terminal first.
5) When raising a heavy component (heavier
than 25 kg), use a hoist or crane. Before
starting work, check that the slings (wire
ropes, chains, and hooks) are free from
damage. Always use slings which have
ample capacity and install them to proper
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.
11)
7)
8)
9)
10)
12)
13)
14)
15)
16)
When removing a cover which is under

internal pressure or under pressure from a
spring, always leave 2 bolts in diagonal
positions. Loosen those bolts gradually
and alternately to release the pressure,
and then remove the cover.
When removing components, be careful
not to break or damage the electrical wiring. Damaged wiring may cause electrical
fires.
When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips
onto the floor, wipe it up immediately. Fuel
or oil on the floor can cause you to slip
and can even start fires.
As a general rule, do not use gasoline to
wash parts. Do not use it to clean electrical parts, in particular.
Be sure to assemble all parts again in their
original places. Replace any damaged
parts and parts which must not be reused
with new parts. When installing hoses and
wires, be sure that they will not be damaged by contact with other parts when the
machine is operated.
When installing high pressure hoses,
make sure that they are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for
high pressure circuits. In addition, check
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
installed.
When assembling or installing parts,
always tighten them to the specified
torques. When installing protective parts
such as guards, or parts which vibrate violently or rotate at high speed, be particul 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
installed correctly.
When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
When measuring hydraulic pressure,
check that the measuring tools are correctly assembled.
Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at
either end of the track.
If the engine is operated for a long time in
a place which is not ventilated well, you
may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
00-200

Safety notice
SEN03921-01
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.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight
of the load and method of slinging. If too
thick wire ropes are used to sling a light
load, the load may slip and fall.
6) Do not sling a load with 1 wire rope alone.
If it is slung so, it may rotate and may slip
out of the rope. Install 2 or more wire
ropes symmetrically.
k Slinging with 1 rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original winding 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 forming 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 allowable 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
sling a load vertically, up to 19.6 kN {2,000
kg} of total weight can be suspended.
This weight is reduced to 9.8 kN {1,000
kg} when the 2 ropes make a hanging
angle of 120. If the 2 ropes sling a 19.6
kN {2,000 kg} load at a lifting angle of
150, each of them is subjected to a force
as large as 39.2 kN {4,000 kg}.
00-200
8)
When installing wire ropes to an angular

load, apply pads to protect the wire ropes.
If the load is slippery, apply proper material to prevent the wire rope from slipping.
9) Use the specified eyebolts and fix wire
ropes, chains, etc. to them with shackles,
etc.
10) Apply wire ropes to the middle portion of
the hook.
q
Slinging near the tip of the hook may
cause the rope to slip off the hook
during hoisting. The hook has the
maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes.

12) When lifting up a load, observe the following.
q
Wind in the crane slowly until wire
ropes are stretched. When settling
the wire ropes with the hand, do not
grasp them but press them from
above. If you grasp them, your fingers
may be caught.
q
After the wire ropes are stretched,
stop the crane and check the condition of the slung load, wire ropes, and
pads.

Safety notice
If the load is unstable or the wire rope

or chains are twisted, lower the load
and lift it up again.
q
Do not lift up the load slantingly.
13) When lifting down a load, observe the following.
q
When lifting down a load, stop it temporarily at 30 cm above the floor, and
then lower it slowly.
q
Check that the load is stable, and
then remove the sling.
q
Remove kinks and dirt from the wire
ropes and chains used for the sling
work, and put them in the specified
place.
SEN03921-01
13) If the hoist stops because of a power failure, turn the power switch OFF. When
turning on a switch which was turned OFF
by the electric shock prevention earth
leakage breaker, check that the devices
related to that switch are not in operation
state.
14) If you find an obstacle around the hoist,
stop the operation.
15) After finishing the work, stop the hoist at
the specified position and raise the hook
to at least 2 m above the floor. Do not
leave the sling installed to the hook.
5.
6.
Precautions for using mobile crane

a Read the Operation and Maintenance
Manual of the crane carefully in advance
and operate the crane safely.
Precautions for using overhead hoist crane
k When raising a heavy part (heavier
than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a
part heavier than 25 kg is indicated
after the mark of 4.
1) Before starting work, inspect the wire
ropes, brake, clutch, controller, rails, over
wind stop device, electric shock prevention earth leakage breaker, crane collision
prevention device, and power application
warning lamp, and check safety.
2) Observe the signs for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the
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 immediately in an emergency.
7.
Selecting wire ropes

1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to
the table below.
Wire ropes
(Standard Z twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal
Allowable load
diameter of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4
The allowable load is one-sixth of the

breaking strength of the rope used
(Safety coefficient: 6).
00-200

Safety notice
SEN03921-01
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner
circuit
1) Disconnection
k For the environment, the air conditioner 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 disconnecting the refrigerant gas circuit and then reuse it.
a Ask professional traders for collecting
and filling operation of refrigerant
(R134a).
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 recovering or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2)
00-200
Example of O-ring (Fitted to every joint of

hoses and tubes)
For tightening torque, see the precautions for

installation in each section of "Disassembly
and assembly".
Connection
1] When installing the air conditioner circuit 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 damaged or deteriorated.
4] When connecting the refrigerant piping, apply compressor oil for refrigerant (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.

How to read the shop manual

q
q
q
1.
SEN03921-01
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.
Materials and specifications are subject to change without notice.
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.

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 disassembly 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.
00-200

SEN03921-01
3.
4.
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 )
Revisions
Revised brochures are shown in the shop manual composition table.
Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol
Item
Safety
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
Weight of parts of component or parts. Caution necessary when

selecting hoisting wire, or when working posture is important, etc.
Tightening
torque
5.
Coat
Oil, coolant
Drain
Remarks
Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during

assembly.
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.
Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
00-200

Explanation of terms for maintenance standard
SEN03921-01
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

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 temporary standard size is set and an allowable difference from that size is indicated.
q
The above size set temporarily is called
the standard size and the range of difference 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.
q
Example:
Standard size
Tolerance
0.022
0.126
120
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)
Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft.
The tightness of fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Standard size
60
Tolerance
Shaft
0.030
0.076
Hole
+0.046
+0
00-200

SEN03921-01
2.
Standard clearance and standard value

The clearance made when new parts are
assembled is called the standard clearance, which is indicated by the range
from the minimum clearance to the maximum clearance.
q
When some parts are repaired, the clearance is generally adjusted to the standard
clearance.
q
A value of performance and function of
new products or equivalent is called the
standard value, which is indicated by a
range or a target value.
q
When some parts are repaired, the value
of performance/function is set to the standard value.
5.
3.
Standard interference
q
When the diameter of a hole of a part
shown in the given standard size and tolerance 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 allowable 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 product 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 various tests or experiences in most cases,
however, it must be judged after considering the operating condition and customer's
requirement.
00-200
10
Clearance limit
Parts can be used until the clearance
between them is increased to a certain
limit. The limit at which those parts cannot
be used is called the clearance limit.
q
If the clearance between the parts
exceeds the clearance limit, they must be
replaced or repaired.
q
6.
Interference limit
The allowable maximum interference
between the hole of a part and the shaft of
another part to be assembled is called the
interference limit.
q
The interference limit shows the repair
limit of the part of smaller tolerance.
q
If the interference between the parts
exceeds the interference limit, they must
be replaced or repaired.
q

Handling of electric equipment and hydraulic component
SEN03921-01
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, connectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fitted 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 (defective contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not
correctly aligned, or because there is corrosion or oxidization of the contact surfaces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connecting and disconnecting the connector about
10 times.
2)
Defective crimping or soldering of connectors

The pins of the male and female connectors are in contact at the crimped terminal
or soldered portion, but if there is excessive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
00-200
11
SEN03921-01
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 soldering may be damaged, or the wiring
may be broken.
4)
High-pressure water entering connector

The connector is designed to make it difficult for water to enter (drip-proof structure), 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-circuited 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 surface 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 compressed 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 compressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air completely before cleaning with compressed air.
00-200
12


3.
SEN03921-01
Removing, installing, and drying connectors and wiring harnesses

1) Disconnecting connectors
1] Hold the connectors when disconnecting.
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 connectors apart.
a Never pull with one hand.
2]
q
When removing from clips

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

clip, pull the connector in a parallel
direction to the clip for removing stoppers.
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 connectors

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 disassembled for a long time, it is particularly easy for improper contact to
occur, so always cover the connector.
00-200
13
SEN03921-01
2)
00-200

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 damage to the connector pins.
Check that there is no damage or
breakage to the outside of the connector.
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 breakage, 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 stopper clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring harness.
For connectors fitted with boots, correct any protrusion of the boot. In
addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position.
a If the connector cannot be corrected 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.
14

3)
Heavy duty wire connector (DT 8-pole, 12pole)

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) horizontally 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
SEN03921-01
q
Disconnection
Connection (Example of
incomplete setting of (a))
00-200
15
SEN03921-01
4)
00-200

Drying wiring harness

If there is any oil or dirt on the wiring harness, 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 follows.
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 connector.
After drying, leave the wiring harness
disconnected and carry out a continuity test to check for any short circuits
between pins caused by water.
a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16

4.
Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These control 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 controller.
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 connectors 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 disconnecting 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 connectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnecessary abnormality displays will be
generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the reading of the tester.
a If there is any change, there is probably defective contact in that circuit.
SEN03921-01
00-200
17
SEN03921-01

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 performance 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 cleaning 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

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 equipment, 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 circuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment cannot remove, so it is an extremely effective
device.
SEN03921-01
00-200
19

Handling of connectors newly used for engines
SEN03921-01

a
1.
Mainly, following engines are object for following connectors.

q
95E-5
q
107E-1
q
114E-3
q
125E-5
q
140E-5
q
170E-5
q
12V140E-3
Slide lock type
(FRAMATOME-3, FRAMATOME-2)
q
95 170, 12V140 engines
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)
2.
Pull lock type (PACKARD-2)

95 170, 12V140 engines
q
Various temperature sensors
Example)
Intake air temperature sensor in
intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR,
etc.
Disconnect the connector by pulling lock
(B) (on the wiring harness side) of connector (2) outward.
Disconnect connector (1) according to the following procedure.

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

3.
SEN03921-01
Push lock type

q
95, 107, 114 engines
Example)
Fuel pressure sensor in common rail
(BOSCH-03)
Disconnect connector (3) according to the following procedure.
1) While pressing lock (C), pull out connector
(3) in the direction of the arrow.
q
114 engine
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.
107 engine
2)
If the lock is on the underside, use

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

SEN03921-01
q
4)
95, 125 170, 12V140 engines

While pressing lock (E) of the connector,
pull out connector (5) in the direction of
the arrow.
Example)
Fuel pressure sensor in common rail:
PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector)

140 engine
Example)
Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
1)
Disconnect connector (6) according to the

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 harness side.
2)
Connect the connector according to the

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)
Injection pressure control valve of fuel
supply pump: PCV (SUMITOMO-2)
Example)
Speed sensor of fuel supply pump:
G (SUMITOMO-3)
a Pull the connector straight up.
00-200
22

How to read electric wire code
SEN03921-01

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 symbols. 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 nominal 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 indicated.)
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)
Type
Symbol
Low-voltage
wire for
automobile
AV
Thin-cover
low-voltage
wire for
automobile
AVS
Heat-resistant low-voltAEX
age wire for
automobile
Material
Conductor
Insulator
Conductor
Annealed copper for electric appliance

Soft polyvinyl chloride
Insulator
Soft polyvinyl chloride
Conductor

Heat-resistant crosslinked
polyethylene
Insulator
Using
temperature
range (C)
Example of use
General wiring
(Nominal No. 5 and above)
30 to +60
General wiring
(Nominal No. 3 and below)
General wiring in extremely
50 to +110 cold district, wiring at high-temperature place
00-200
23

SEN03921-01
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
CovAV
Standard
4.6
er D
AEX
Standard
2.0
2.2
2.7
3.0
3.1
3.8
4.6
Nominal No.
Number of
strands/Diameter of strand
Conductor
Sectional
area (mm2)
d (approx.)
AVS
Standard
CovAV
Standard
er D
AEX
Standard
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7
5.5
5.3
4.8
7.0
7.0
6.0
8.2
8.2
8.0
10.8
10.8
8.6
11.4
11.4
9.8
13.0
13.0
10.4
13.6
13.6
12.0
16.0
16.0
13.6
17.6
17.6
108/0.80 127/0.80 169/0.80 217/0.80
f of nominal No. denotes flexible.
00-200
24

3.
SEN03921-01
Color codes table
(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR
Color of wire
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red
Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW
Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow &Green
Yellow & Blue
Yellow & Red
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
Charge
Ground
Start
Light
Instrument
Signal
Type of
circuit
Others
AVS or AV
R
B
R
RW
Y
G
L
Br
Lg
O
Gr
P
Sb
Dg
Ch
AEX
R
B
R
D
Y
G
L
WG
RB
YR
GW
LW
BrW
LgR
RY
YB
GR
LR
BrR
LgY
RG
YG
GY
LY
BrY
LgB
RL
YL
GB
LB
BrB
LgW
YW
GL
Gr
Br
00-200
25

Precautions when carrying out operation
SEN03921-01
[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.
q
q
q
q
q
q
q
q
q
q
Precautions when carrying out removal work

If the coolant contains antifreeze, dispose of it correctly.
After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number and thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
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
number
02
03
04
05
06
10
12
2)
00-200
Sleeve nut (elbow end)
07376-70210
07376-70315
07376-70422
07376-70522
07376-70628
07376-71034
07376-71234
02789-20210
02789-20315
02789-20422
02789-20522
02789-20628
07221-21034
07221-21234
Split flange type hoses and tubes

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

2.
q
q
q
q
q
q
q
q
q
q
q
q
q
a
3.
SEN03921-01
Precautions when carrying out installation work

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive.
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.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
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.
When using the machine for the first time after repair or long storage, follow the same procedure.
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 specified 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.
00-200
27
SEN03921-01
4)
5)
00-200

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.
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.
28

Method of disassembling and connecting push-pull type coupler
SEN03921-01

k
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.
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.
00-200
29
SEN03921-01

Type 2
1.
2.
Disconnection
1) Hold the tightening portion and push body
(7) straight until sliding prevention ring (6)
contacts contact surface (a) of the hexagonal 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 disconnect it. (Fig. 8)
Connection
Hold the tightening portion and push body
contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
00-200
30

SEN03921-01
Type 3
1.
2.
Disconnection
1) Hold the tightening portion and push body
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10)
2) While holding the condition of Step 1),
push cover (10) straight until it contacts
contact surface (b) of the hexagonal portion at the male end. (Fig. 11)
3) While holding the condition of Steps 1)
and 2), pull out whole body (9) to disconnect it. (Fig. 12)
Connection
Hold the tightening portion and push body
(9) straight until the sliding prevention ring
contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
00-200
31

Standard tightening torque table
SEN03921-01

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

mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39
a
Width across flats

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

mm
6
8
10
12
a Fig. A
Width across flats

mm
10
12
14
17
Tightening torque
Nm
5.9 9.8
13.7 23.5
34.3 46.1
74.5 90.2
kgm
0.6 1.0
1.4 2.4
3.5 4.7
7.6 9.2
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

2.
Table of tightening torques for split flange bolts

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

mm
10
12
16
3.
Width across flats

mm
14
17
22
Tightening torque
Nm
kgm
59 74
6.0 7.5
98 123
10.0 12.5
235 285
23.5 29.5
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.
Nominal No.
02
03,04
05,06
10,12
14
4.
SEN03921-01
Thread diameter
mm
14
20
24
33
42
Width across flats

mm
Tightening torque Nm {kgm}

Range
Target
35 63 { 3.5 6.5}
44 { 4.5}
84
132
{
8.5
13.5}
103
{10.5}
Varies depending
on type of connec- 128 186 {13.0 19.0}
157 {16.0}
tor.
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}
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
No.
08
10
12
14
16
18
20
24
30
33
36
42
52
Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52
Width across flats

mm
14
17
19
22
24
27
30
32
32
36

Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.81 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}
00-200
33

SEN03921-01
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.
Nominal
No. of
hose
Width
across
flats
02
19
22
24
27
32
36
41
46
55
03
04
05
06
(10)
(12)
(14)
6.
Range
34 54 { 3.5 5.5}
34 63 { 3.5 6.5}
54 93 { 5.5 9.5}
59 98 { 6.0 10.0}
84 132 { 8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}
Target
44 { 4.5}
74 { 7.5}
78 { 8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}
Taper seal
Thread size
(mm)
14
18
22
24
30
33
36
42
Face seal
Nominal No.
Thread
Number of
diameter (mm)
threads, type of
(Reference)
thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UNS
25.4
1-3/16-12UN
30.2
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
diameter
of pipe
(mm)
Width
across
flats
(mm)
8
10
12
15 (16)
22 (20)
19
22
24 (27)
30 (32)
36

Range
Target
14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}
15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}
Face seal
Thread diameter
Nominal No.
(mm)
Number of threads,
(Reference)
type of thread
9/16-18UN
14.3
11/16-16UN
17.5
13/16-16UN
20.6
1-14UN
25.4
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
Bolts and nuts
Thread size
mm
6
8
10
12
14
00-200
34
Nm
10 2
24 4
43 6
77 12
kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22

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
mm
6
8
10
12
14
9.
SEN03921-01
Tightening torque
Nm
82
10 2
12 2
24 4
36 5
kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51
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.
Material
Thread size (inch)
1/16
1/8
1/4
3/8
1/2
3/4
Tightening torque
In cast iron or steel
In aluminum
Nm
kgm
Nm
kgm
15 2
1.53 0.20
51
0.51 0.10
20 2
2.04 0.20
15 2
1.53 0.20
25 3
2.55 0.31
20 2
2.04 0.20
35 4
3.57 0.41
25 3
2.55 0.31
55 6
5.61 0.61
35 4
3.57 0.41
75 8
7.65 0.82
45 5
4.59 0.51
00-200
35

Conversion table
SEN03921-01
Conversion table
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 horizontal 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
(A)
00-200
(B)
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
36
5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740
6
0.236
0.630
1.024
1.417
1.811
1 mm = 0.03937 in
7
8
9
0.276
0.315
0.354
0.669
0.709
0.748
1.063
1.102
1.142
1.457
1.496
1.536
1.850
1.890
1.929
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898

Conversion table
SEN03921-01
Millimeters to inches
1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
0
10
20
30
40
0
0
0.394
0.787
1.181
1.575
1
0.039
0.433
0.827
1.220
1.614
2
0.079
0.472
0.866
1.260
1.654
3
0.118
0.512
0.906
1.299
1.693
4
0.157
0.551
0.945
1.339
1.732
5
0.197
0.591
0.984
1.378
1.772
6
0.236
0.630
1.024
1.417
1.811
7
0.276
0.669
1.063
1.457
1.850
50
60
70
80
90
1.969
2.362
2.756
3.150
3.543
2.008
2.402
2.795
3.189
3.583
2.047
2.441
2.835
3.228
3.622
2.087
2.480
2.874
3.268
3.661
2.126
2.520
2.913
3.307
3.701
2.165
2.559
2.953
3.346
3.740
2.205
2.598
2.992
3.386
3.780
2.244
2.638
3.032
3.425
3.819
1 kg = 2.2046 lb
6
7
8
9
13.23
15.43
17.64
19.84
35.27
37.48
39.68
41.89
57.32
59.53
61.73
63.93
79.37
81.57
83.78
85.98
101.41 103.62 105.82 108.03
2.283
2.677
3.071
3.465
3.858
2.323
2.717
3.110
3.504
3.898
Kilogram to pound
0
10
20
30
40
0
0
22.05
44.09
66.14
88.18
1
2.20
24.25
46.30
68.34
90.39
2
4.41
26.46
48.50
70.55
92.59
3
6.61
28.66
50.71
72.75
94.80
4
8.82
30.86
51.91
74.96
97.00
5
11.02
33.07
55.12
77.16
99.21
50
60
70
80
90
110.23
132.28
154.32
176.37
198.42
112.44
134.48
156.53
178.57
200.62
114.64
136.69
158.73
180.78
202.83
116.85
138.89
160.94
182.98
205.03
119.05
141.10
163.14
185.19
207.24
121.25
143.30
165.35
187.39
209.44
0
10
20
30
40
0
1
2
0
0.264
0.528
2.642
2.906
3.170
5.283
5.548
5.812
7.925
8.189
8.454
10.567 10.831 11.095
3
0.793
3.434
6.076
8.718
11.359
4
1.057
3.698
6.340
8.982
11.624
1 l = 0.2642 U.S.Gal
5
6
7
8
9
1.321 1.585
1.849
2.113
2.378
3.963 4.227
4.491
4.755
5.019
6.604 6.869
7.133
7.397
7.661
9.246 9.510
9.774 10.039 10.303
11.888 12.152 12.416 12.680 12.944
50
60
70
80
90
13.209
15.850
18.492
21.134
23.775
14.001
16.643
19.285
21.926
24.568
14.265
16.907
19.549
22.190
24.832
14.529
17.171
19.813
22.455
25.096
123.46
145.51
167.55
189.60
211.64
125.66
147.71
169.76
191.80
213.85
127.87
149.91
171.96
194.01
216.05
130.07
152.12
174.17
196.21
218.26
Liters to U.S. Gallons
13.473
16.115
18.756
21.398
24.040
13.737
16.379
19.020
21.662
24.304
14.795
17.435
20.077
22.719
25.361
15.058
17.700
20.341
22.983
25.625
15.322
17.964
20.605
23.247
25.889
15.586
18.228
20.870
23.511
26.153
00-200
37

Conversion table
SEN03921-01
Liters to U.K. Gallons

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

Conversion table
SEN03921-01
kg/cm2 to lb/in2
0
10
20
30
40
0
0
142.2
284.5
426.7
568.9
1
14.2
156.5
298.7
440.9
583.2
2
28.4
170.7
312.9
455.1
597.4
3
42.7
184.9
327.1
469.4
611.6
4
56.9
199.1
341.4
483.6
625.8
5
71.1
213.4
355.6
497.8
640.1
6
85.3
227.6
369.8
512.0
654.3
1 kg/cm2 = 14.2233 lb/in2

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

Conversion table
SEN03921-01
Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade 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 Fahrenheit 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 Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
F
40.4
37.2
34.4
31.7
28.9
40
35
30
25
20
40.0
31.0
22.0
13.0
4.0
11.7
11.1
10.6
10.0
9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
177.8
179.6
181.4
183.2
185.0
28.3
27.8
27.2
26.7
26.1
19
18
17
16
15
2.2
0.4
1.4
3.2
5.0
8.9
8.3
7.8
7.2
6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
25.6
25.0
24.4
23.9
23.3
14
13
12
11
10
6.8
8.6
10.4
12.2
14.0
6.1
5.6
5.0
4.4
3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
22.8
22.2
21.7
21.1
20.6
9
8
7
6
5
15.8
17.6
19.4
21.2
23.0
3.3
2.8
2.2
1.7
1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
20.0
19.4
18.9
18.3
17.8
4
3
2
1
0
24.8
26.6
28.4
30.2
32.0
0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
17.2
16.7
16.1
15.6
15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
14.4
13.9
13.3
12.8
12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
00-200
40

Conversion table
SEN03921-01
00-200
41
SEN03921-01

2009 KOMATSU
All Rights Reserved
Printed in Japan 06-09 (01)
00-200
42
SEN03922-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
01 Specification

Specification dimension drawing..................................................................................................................... 3
Specifications .................................................................................................................................................. 4
Weight table .................................................................................................................................................... 8
Table of fuel, coolant and lubricants.............................................................................................................. 10
01-100
SEN03922-01
01-100

Specification dimension drawing
SEN03922-01
Specification dimension drawing
Item
Unit
WA320-6
WA320PZ-6
Machine weight
kg
14,085
15,200
Normal load
kg
4,480
4,320
Bucket capacity (heaped)
2.8
2.7
Engine model
Komatsu SAA6D107E-1 Diesel engine
kW{HP}/rpm
125 {167}/2,000
127.3 {171}/2,000
Engine rated output

Net [ISO 9249/SAE J1349] (*1)
Gross [SAE J1995] (*2)
A Overall length
mm
7,515
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
mm
2,740
2,750
Bucket width
G Dumping clearance (*3)
Bucket tip/BOC tip
mm
2,940/2,850
2,865/2,795
H Dumping reach (*3)
Bucket tip/BOC tip
mm
990/1,035
1,100/1,135
Bucket dump angle (max. height)

Min. turning radius
Bucket tip/BOC tip

Center of outside tire
45
48
mm
6,225/6,260
6,120/6,150
mm
5,380
5,380
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
18.7/18.7
18.7/18.7
38.0/38.0
38.0/38.0
Permissible towing load
Travel speed
degree
3rd (forward/reverse)
4th (forward/reverse)
km/h
*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.
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
01-100

Specifications
SEN03922-01
Weight
Specifications
Machine model name
WA320-6
WA320PZ-6
Serial No.
70001 and up
70001 and up
Machine weight
kg
14,085
15,200
Machine weight (front wheel) in

SAE travel posture
kg
5,730
6,940
Machine weight (rear wheel) in

SAE travel posture
kg
8,355
8,260
Bucket capacity (heaped)
m3
2.8
2.7
Normal load
kg
4,480
4,320
km/h
4.0 13.0
13.0
18.7
38.0
4.0 13.0
13.0
18.7
38.0
km/h
4.0 13.0
13.0
18.7
38.0
4.0 13.0
13.0
18.7
38.0
kN{kg}
120 {12,200}
120 {12,200}
120 {12,200}
120 {12,200}
Gradeability
deg.
25
25
Min. turning radius

(center of outside tire)
mm
5,380
5,380
Turning radius (cutting edge/BOC tip),

SAE travel posture
mm
6,225/6,260
6,120/6,150
Overall length (with BOC)
mm
7,515
7,770
Overall width (chassis)
mm
2,590
2,590
Bucket width (with BOC)
mm
2,740
2,750
Overall height (cab top)
mm
3,200
3,200
Overall height with bucket lifted up
mm
5,325
5,475
Dimension
Performance
Travel speed
Forward 1st
Forward 2nd
Forward 3rd
Forward 4th
Reverse 1st
Reverse 2nd
Reverse 3rd
Reverse 4th
Max. traction force

Forward
Reverse
Wheelbase
mm
3,030
3,030
Tread
mm
2,050
2,050
Minimum ground clearance
mm
425
425
Max. hinge pin height
mm
3,905
4,005
Dumping clearance (*1)

(cutting edge/BOC tip)
mm
2,940/2,850
2,865/2,795
Dumping reach (*1)

mm
990/1,035
1,100/1,135
Steering angle
deg.
38.5 (frame stopper 40)
38.5 (frame stopper 40)
Bucket tilt angle

(operating posture/max. height)
deg.
47/62
47/66
Bucket dump angle

(max. height)
deg.
45
48
Digging depth, 10
mm
250/295
330/370
*1: Indicates the value at the 45 bucket dump angle.

01-100

Specifications
Machine model name
WA320-6
WA320PZ-6
Serial No.
70001 and up
70001 and up
Model
SAA6D107E-1
Type
4-cycle, water-cooled, in-line vertical, direct injection type

with turbocharger and air-cooled aftercooler
No. of cylinders bore x stroke
mm
6 107 x 124
l {cc}
6.69 {6,690}
kW{HP}/rpm
125 {167}/2,000
127.3 {171}/2,000
Nm{kgm}/rpm
660 {67.3}/1,500
g/kWh
{g/HPh}
224 {167}
Max. speed at no load
rpm
2,250
Min. speed at no load
rpm
825
Performance
Total piston displacement
Engine
SEN03922-01
Rated output
Net [ISO 9249/SAE J1349] (*1)
Gross [SAE J1995] (*2)
Max. torque (*1)
Min. fuel consumption ratio
Starting motor
24 V, 5.5 kW
Alternator
24 V, 60 A
Battery (*3)
12 V, 140 Ah x 2 pieces
HST pump
Type
Pump capacity
Variable displacement swash plate type piston pump

cc/rev
0 110
HST motor 1
Power train
Type
Motor capacity
Variable displacement bent axis type piston motor

cc/rev
HST motor 2
Type
Motor capacity
Variable displacement bent axis type piston motor

cc/rev
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
Axle
59 128
Counter-shaft double acting planetary type, spur gear
constant-mesh type, switching between 2 power trains
Transfer
Front and rear wheel drive
Front axle
Fixed frame, semi-float type
Rear axle
Center pin support type, semi-float type
Size
Tire
0 140
20.5 25 12PR
Rim size
Inflation pressure
Front wheel
Rear wheel
25 x 17.00 1.7
kPa
{kg/cm2}
330 {3.3}
280 {2.8}
*1:
*2:
*3:
a
Indicates the value at the lowest cooling fan speed.

Indicates the value of the engine alone (without cooling fan).
The battery capacity (Ah) is indicated in the 5-hour rate value.
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
01-100

Specifications
SEN03922-01
Machine model name
WA320-6
WA320PZ-6
Serial No.
70001 and up
70001 and up
Brake
Main
Braking method
4-wheel brake, independent front and rear wheel brakes
Type of brake
Enclosed wet multiple disc type
Drive method
Hydraulic drive
Operating method
Foot-operated (with hydraulic booster)
Parking
Braking method
Transmission output shaft brake
Type of brake
Wet multiple disc type
Drive method
Mechanical type
Steering
Operating method
Manual lever type
Steering method
Articulated chassis type
Drive method
Hydraulic drive
Steering pump
Type
Delivery
Gear type
cm /rev
90.7
Hydraulic pump
Work equipment pump

Type
Delivery
Gear type
cm /rev
32.0
Brake and cooling fan pump

Type
Delivery
Gear type
cm /rev
18.1
Transfer lubrication pump

Type
Delivery
Gear type
cm3/rev
12.0
Hydraulic equipment
Steering cylinder
Type
Cylinder bore
Double-acting piston type

mm
Piston rod outside diameter
mm
40
Stroke
mm
453
Max. distance between centers

of pins
mm
1,271
Min. distance between centers

of pins
mm
818
Lift cylinder
Cylinder
Type
Bucket cylinder
Cylinder bore
mm
140
140
mm
75
75
Stroke
mm
740
729

of pins
mm
1,969
2,056

of pins
mm
1,229
1,327
Type
01-100
70
Cylinder bore
mm
160
180
mm
80
110
Stroke
mm
532
558

of pins
mm
1,559
1,912

of pins
mm
1,027
1,354

Specifications
SEN03922-01
Machine model name
WA320-6
WA320PZ-6
Serial No.
70001 and up
70001 and up
Coupler plunger
Cylinder
Type
mm
35
mm
20
Stroke
mm
214
Max. distance between

centers of pins
mm
586
Min. distance between

centers of pins
mm
372
Work equipment control valve

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

<with reversible valve and flow control valve>
Type
Type of link
Shape of bucket cutting edge
cm3/rev
14.5
Z-bar link
Parallel movement type

Z-bar link
Straight cutting edge with

BOC
Straight cutting edge with

BOC
01-100

Weight table
SEN03922-01
Weight table
k
This weight table is prepared for your reference when handling or transporting the components.
Unit: kg
Machine model name
WA320-6
WA320PZ-6
Serial No.
70001 and up
70001 and up
Engine (excluding coolant and oil)
625
625
Damper
Cooling assembly (excluding coolant and oil)

Radiator
Oil cooler
Aftercooler
82
14
14
10
82
14
14
10
Transfer oil cooler
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
Front axle
With torque proportioning differential
With limited slip differential
714
718
714
718
Rear axle
With torque proportioning differential
With limited slip differential
666
674
666
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

2-spool valve
3-spool valve
65
91
Work equipment PPC valve
Attachment PPC valve
Priority valve
Orbit-roll valve
Cushion valve
Charge valve
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

Weight table
SEN03922-01
Unit: kg
Machine model name
WA320-6
WA320PZ-6
Serial No.
70001 and up
70001 and up
Front frame
1,100
1,252
Rear frame
973
973
1,695
1,950
255
220
Counterweight
Additional counterweight (1 piece)
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
1,231
1,139
Operator's cab
(including air conditioner and interior parts)
825
825
Operator seat
41
41
Air conditioner unit
Battery (1 piece)
47
47
Bucket
2.8 m3 (including BOC)
2.7 m3 (including BOC)
01-100

Table of fuel, coolant and lubricants
SEN03922-01

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

SEN03922-01
01-100
11
SEN03922-01

2009 KOMATSU
All Rights Reserved
01-100
12
SEN03923-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
10 Structure, function and

maintenance standard
10

Engine mount and transfer mount................................................................................................................... 2
Damper ........................................................................................................................................................... 3
Cooling system ............................................................................................................................................... 4
Cooling system hydraulic piping diagram ....................................................................................................... 5
Cooling fan motor............................................................................................................................................ 7
10-100
SEN03923-01
Engine mount and transfer mount
10-100

Engine mount and transfer mount

Damper
SEN03923-01
Damper
Unit: mm
No.
Check item
Distance between HST pump

installation surface and boss tip
Wear on internal teeth of coupling

(resin)
3. Coupling
4. Boss
5. HST pump input shaft
6. Cover
7. Flywheel
Criteria
Remedy
Standard size
Repair limit
74.9
0.8
Repair limit: 1.0
Adjust
Replace
Outline
q
The damper protects the drive systems on and
after the engine from torsional vibrations by
reducing the torsional vibrations of the engine
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).
10-100

Cooling system
SEN03923-01
Cooling system
1. Reservoir tank
2. Oil cooler
3. Radiator cap
4. Radiator
5. Aftercooler
6. Transfer oil cooler
7. Cooling fan
8. Cooling fan motor
Specifications
Core type
Fin pitch (mm)
Total heat dissipation area
(m2)
Pressure valve cracking pressure
(kPa {kg/cm2})
Vacuum valve cracking pressure
(kPa {kg/cm2})
Radiator
Oil cooler
Aftercooler
CF68-4
<CF73>
3.5/2
<8.0/2>
35.03
<24.36>
70.0
{0.7}
0 5.0
{0 0.05}
CF40-1
<CF74-1>
3.5/2
<8.0/2>
4.84 x 3
<3.25 x 3>
AL WAVE
<CF75>
4.0/2
<8.0/2>
12.79
<9.69>
Values in < > are shown for wide core type (if equipped).
10-100

Cooling system hydraulic piping diagram
SEN03923-01

2. Strainer
3. Hydraulic tank
4. Brake and cooling fan pump
5. Charge valve
Outline
q
Cooling fan motor (1) installed in the machine
rear side is driven by oil pressure from brake
and cooling fan pump (4).
10-100
SEN03923-01
10-100


Cooling fan motor
SEN03923-01
Cooling fan motor
Type: LMF16
P: From pump through charge valve

T: To hydraulic tank through return filter
TC: To hydraulic tank
1. ER terminal
2. EF terminal
3. Solenoid proportional pilot valve
4. ON/OFF pilot valve
Specifications
Type: LMF16
Capacity: 14.5 cm3/rev
Rated speed: 1,800 rpm
Rated flow rate: 26.1 l/min
10-100
SEN03923-01
10-100

Cooling fan motor

Cooling fan motor
SEN03923-01
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
Standard size
18 Spool return spring
19 Spool return spring
Repair limit
Free length x
Outside
diameter
Installed
length
Installed load
Free length
Installed load
44.84 x 12
33
58.8 N
{6 kg}
47.1 N
{4.8 kg}
35 x 8.5
34
44.1 N
{4.5 kg}
35.3 N
{3.6 kg}
If damaged or
deformed, replace
spring
10-100
SEN03923-01

Cooling fan motor
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 center and bottom dead center of the stroke of piston (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

Cooling fan motor
SEN03923-01

1) Suction function
Function
q
If the fan pump stops, the pressurized oil does
not flow into the motor.
q
Since the motor continues revolution because
of the force of inertia, however, the pressure on
the outlet side of the motor rises.
q
When the pressurized oil stops flowing in from
inlet port (P), suction safety valve (1) sucks in
the pressurized oil on the outlet side and supplies it to port (MA) where there is not sufficient
oil to prevent cavitation.
(2) When the pump is stopped

q
When the engine stops, the input revolution of
the pump becomes 0 rpm.
q
The pressurized oil from the pump is not supplied to port (P).
q
As the pressurized oil is not supplied to (MA)
side of the motor, the motor speed lowers
gradually to stop.
q
If the motor shaft is revolved by the force of
inertia while the oil flow in port (P) is reducing,
the oil in port (T) on the outlet side is sent by
suction safety valve (1) to (MA) side to prevent
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.
10-100
11
SEN03923-01

Cooling fan motor
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
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.
q
10-100
12

Cooling fan motor
SEN03923-01
3. Operation of reversible valve

1) When the ON/OFF solenoid is
de-energized
q
q
q
q
When ON/OFF solenoid (1) is "de-energized",

the pressurized oil from the pump is shut off by
valve (2).
Port (C) opens for the hydraulic tank circuit.
Spool (3) is pushed to the right by spring (4).
Port (MA) opens and pressurized oil flows in to
revolve the motor in forward (clockwise).
2) When the ON/OFF solenoid is energized

q
q
q
q
q
When ON/OFF solenoid (1) is "energized",

valve (2) is switched.
The pressurized oil from the pump flows to
spool chamber (D) through port (C).
The pressurized oil in chamber (D) compresses spring (4).
Spool (3) moves to the left.
Port (MB) opens and pressurized oil flows in to
rotate the motor in reverse (counterclockwise).
10-100
13
SEN03923-01

Cooling fan motor
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
q
q
The motor speed increases in proportion to the

increase of the incoming oil (Q) as shown in
Fig. 1.
When the incoming flow rate is (Q1), motor
speed becomes (B) rpm.
In order to reduce noise and loss of the motor,
this valve keeps the fan speed constant independent of the flow rate to the motor.
Even if the flow rate is increased from (Q0) to
(Q1), the valve maintains the motor speed constant between points (A) and (C).
Operation
q
For the flow control valve, the upstream pressure 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 orifice (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 connected 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-variable type.
q
As shown in Fig. 2, it is possible to change the
flow control valve continuously while maintaining 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

Cooling fan motor
SEN03923-01
10-100
15
SEN03923-01

2009 KOMATSU
All Rights Reserved
10-100
16
SEN03924-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up

10
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
10-200
SEN03924-01
10-200
200 Power train
200 Power train

Power train
SEN03924-01
Power train
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
10-200
SEN03924-01
Power train system diagram
10-200
200 Power train

200 Power train

1. Engine
2. Damper
3. HST pump
4. Steering pump
5. Work equipment pump
7. Transfer lubrication pump
8. High-pressure hose
9. HST motor 1
10. HST motor 2
11. Emergency steering valve (if equipped)
12. Transfer
13. Transfer clutch
14. Parking brake
16. Front axle
17. Differential
18. Wet multiple disc type brake
19. Final drive
20. Front tire
21. Rear drive shaft
22. Rear axle
23. Differential
25. Final drive
26. Rear tire
SEN03924-01
Outline
q
The power from engine (1) is transmitted to
HST pump (3) after its torsional vibrations have
been reduced with damper (2) installed on the
flywheel.
q
The power from engine (1) is also transmitted
to HST pump (3) and the HST charge pump
being built in HST pump (3) as well as steering
pump (4), work equipment pump (5), brake
and cooling fan pump (6) and transfer lubrication pump (7) being connected to HST pump
(3).
q
The directional selector valve and servo piston
installed on HST pump (3) continuously modify
the oil discharge direction and discharged
amount responding to inclination of the swash
plate.
q
HST motors (9) and (10) are installed on transfer (12) and connected to HST pump (3)
through high-pressure hose (8).
q
The hydraulic power from HST pump (3)
changes the rotating direction and speed of
HST m oto rs (9) and (1 0) to cont ro l th e
machine forward and reverse travel and travel
speed.
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 transmitted 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 differentials (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.
10-200
SEN03924-01
Drive shaft
1. Front axle
3. Transfer
4. Rear drive shaft
5. Rear axle
10-200
200 Power train

Drive shaft
Outline
q
The power from the transfer output shaft is
transmitted to front axle (1) and rear axle (5)
through front drive shaft (2) and rear drive
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.
200 Power train

HST hydraulic piping diagram
SEN03924-01
HST hydraulic piping diagram
1. Hydraulic tank
2. HST pump
3. Clutch solenoid valve
4. HST oil filter
5. HST motor 1
6. HST motor 2
10-200
SEN03924-01
200 Power train

HST pump
HST pump
HST: Abbreviation for HydroStatic Transmission
1. Directional selector solenoid valve

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

HST pump
SEN03924-01
Operation
Flow of power
q
q
q
q
The HST pump is installed on the damper of

the engine flywheel.
the HST pump through the flywheel and
damper.
The HST pump is equipped with directional
selector solenoid valve (1) and servo cylinder
(6).
Driving the machine forward or reverse activates directional selector solenoid valve (1),
tilting swash plate (11) and, as a result, causing the switch between the oil suction and discharge ports.
The HST pump is built-in cylinder block and 9
pistons (10) rotate along with drive shaft (12).
Tips of piston (10) slides on the swash plate
surface of swash plate (11) that does not
rotate.
Flow of oil
q
q
Inclination of swash plate (11) starts reciprocating movement of piston (10). The pumping
action initiated by this reciprocating movement
suctions or discharges the oil in cylinder block
(9) continuously.
The pumping action directs the oil flow in a certain definite direction so that it may flow to the
HST motor.
Reversing the inclination of swash plate (11)
reverses the suction and discharge ports and,
as a result, reversing the oil discharging direction, too.
Piston (10) does not stroke when swash plate
(11) is at neutral, thus the oil is not discharged.
Increasing or decreasing the inclination (angle)
of swash plate (11) changes the stroke of piston (10), allowing to control the travel speed.
If the amount of the oil in the low-pressure circuit (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).
10-200
SEN03924-01
1. Nut
2. Locknut
3. Poppet spring
4. Check spring
5. Main piston
6. Valve seat
7. Pilot poppet
8. Adjustment screw
10-200
10
200 Power train

HST pump
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 pressure
to the low pressure circuit side.
This valve sets the maximum pressure of the
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.
200 Power train

HST pump
SEN03924-01
Operation
q
q
q
Port (A) is connected to the high pressure circuit side of the HST pump, and ports (C) and
(D) are connected to the low pressure circuit
side of the pump.
Oil fills up chamber (B) after flowing through
the orifice of main piston (5).
Pilot poppet (7) is seated on valve seat (6).
If oil pressure in port (A) and chamber (B) goes
beyond the set pressure, pilot poppet (7) is
pushed in the left direction. As a result, the oil
pressure in chamber (B) is released to port (C)
through chamber (D) and the oil pressure in
chamber (B) is decreased.
As the oil pressure in chamber (B) goes lower,

the orifice of main piston (5) is activated and
differential pressure is generated in port (A)
and chamber (B).
The oil pressure in port (A) pushes main piston
(5) in the left direction, relieving the abnormal
pressure generated in port (A) to port (C).
As the oil pressure in port (A) goes lower than
that in port (C), check spring (4) pushes back
main piston (5) in the right direction.
The oil in port (C) is conducted to port (A)
through chamber (D) so that the oil level in port
(A) may not go low.
Increasing or decreasing the repulsive force of
poppet spring (3) allows adjusting the set pressure.
When increasing the set pressure, remove the
nut to loosen the locknut and screw the adjustment screw. When decreasing, loosen the
adjustment screw.
10-200
11
200 Power train

HST pump
SEN03924-01
When increasing the set pressure, loosen locknut (1) and screw adjustment screw (2). When
decreasing, loosen the adjustment screw.
1. Locknut
2. Adjustment screw
3. Piston
4. Spring
Function
q
oil pressure on the low pressure circuit side
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
q
Port (A) is connected to the HST pump charge

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

HST pump
SEN03924-01
HST charge pump
1. Cover bolt
2. Pump gear
3. Key
4. Coupling
5. Drive shaft
6. Plate
7. Charge pump cover
8. Crescent separator plate
Outline
q
This pump is installed on the HST pump. It,
working in conjunction with the HST pump,
supplies oil to the HST speed-related valve
and the low-pressure relief valve on the HST
pump.
Specifications
Type
Gear pump
(inscription type)
(cc/rev)
28.3
Function
q
This pump is connected to the HST pump drive
shaft (5) with coupling (4). Pumping action is
turned on as it is rotated.
q
It contains pump gear (2) and crescent separator plate (8) to suction or delivery oil continuously in the direction shown in the figure.
10-200
13
SEN03924-01
Speed-related valve (DA valve)
200 Power train

HST pump
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 solenoid 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
200 Power train

HST pump
SEN03924-01
High-pressure cutoff valve
1. Adjustment screw
2. Locknut
3. Spring
4. Spool
5. Piston
6. Barrel
7. Shuttle spool
8. Valve seat
Function
q
oil pressure on the high pressure circuit side
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 forward 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 protected.
10-200
15
200 Power train

HST motor
SEN03924-01
HST motor
a
HST: Abbreviation for HydroStatic Transmission
HST motor 1
1. Drive shaft
2. Piston
3. Cylinder block
4. Port plate
5. EP servo valve
10-200
16
Specifications
Model name
Type
A6VM140EP
Variable displacement bent
axis type piston motor
0 140
(cc/rev)
set pressure
44.1 {450}
(MPa {kg/cm2})
High-pressure cutoff
Effective differential pressure
valve set pressure
40.7 {415}
2
(MPa {kg/cm })
set pressure
3.0 {31}
(MPa {kg/cm2})
200 Power train

HST motor
SEN03924-01
HST motor 2
1. Drive shaft
2. Piston
3. Cylinder block
4. Port plate
5. HA servo valve
6. Directional shuttle valve
Specifications
Model name
A6VM140HA
Type
Variable displacement bent

axis type piston motor
59 128
(cc/rev)
set pressure
44.1 {450}
(MPa {kg/cm2})
High-pressure cutoff
Effective differential pressure
valve set pressure
40.7 {415}
(MPa {kg/cm2})
set pressure
3.0 {31}
(MPa {kg/cm2})
10-200
17
SEN03924-01
Principle
q
It is assumed that the shaft of the disc is supported to enable free rotation of the disc. Force
F being applied aslant to the disc is divided
into force F1 orthogonal to the disc and force
F2 that works in the circumferential direction of
the disc. Force F1 pushes the disc in the axial
direction and force F2 rotates the disc clockwise.
q
Also when force F' works on the disc instead of
force F, it is likewise divided into force F1' and
F2'. Force F2' rotates the disc counterclockwise.
200 Power train

HST motor
Operation
q
Pressurized oil from the HST pump flows to the
back side of piston (2) through the HST motor
inlet port, and is activated by inclination of piston (2) and cylinder block (3) as the rotating
force of drive shaft (1).
q
As the HST motor is rotated forward or
reverse, the oil in the high pressure circuit side
is conducted to the directional shuttle valve (6).
q
As a large load is applied to the motor being
connected to servo valve (5), the pressure difference is generated between the high pressure 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 shuttle valve (6) work to increase inclination of cylinder block (3) and piston (2), reducing the
revolving speed and increasing the torque.
10-200
18
200 Power train

HST motor
SEN03924-01
EP servo valve
1. Motor 1 solenoid valve

2. EP servo valve
3. Spring
4. Servo cylinder
Function
q
This valve is installed on the rear side of HST
motor 1. It controls the motor displacement
depending on the current value given to motor
1 solenoid valve (1).
Operation
q
Suction force F1 of motor 1 solenoid valve (1)
and force F2 of spring (3) are applied to EP
servo valve (2).
q
When the current value given to motor 1 solenoid valve (1) is small (when F1 < F2), EP
servo valve (2) conducts the oil pressure on
the motor high pressure side circuit to the
small diameter side (S) of servo cylinder (4)
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 solenoid 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 displacement).
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.
10-200
19
SEN03924-01
HA servo valve
1. Motor 2 solenoid valve

2. HA servo valve
3. Servo cylinder
Function
q
This valve is installed in the rear side of HST
motor 2. In order to bring out the motor output
corresponding to the external load to the
motor, it controls the motor displacement using
the oil pressure of the circuit being selected
from the directional shuttle valve.
10-200
20
200 Power train

HST motor
Operation
q
If the load to the motor is small, HA servo valve
(2) conducts oil pressure to the small diameter
side (S) through the directional shuttle valve
and releases the oil pressure on the large
diameter side (L) to the tank (motor housing).
Servo cylinder (3) moves toward the min side,
minimizing the motor displacement.
q
If a large load is applied to the motor during, for
instance, uphill travel, HA servo valve (2) is
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 diameter side (L) independent of the magnitude of
the load to the motor to set the motor displacement to the maximum.
200 Power train

HST motor
SEN03924-01
Directional shuttle valve
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 referencing the incoming signal, which corresponds
to the directional signal of the directional selector solenoid valve on the HST pump.
Above process reduces the decelerating
impacts that results when the oil pressure is
switched.
Operation
Directional selector solenoid valve (1) interlocks 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 controls the destination of the oil pressure to work
on the HA servo valve.
q
10-200
21
SEN03924-01
Transfer
200 Power train

Transfer
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
200 Power train

Transfer
1. HST motor 1
2. Input shaft
3. Transfer clutch
4. Carrier
5. Ring gear (number of teeth: 86)
6. Planetary pinion (number of teeth: 24)
7. Planetary shaft
8. Motor 1 gear (number of teeth: 50)
SEN03924-01
9. Sun gear (number of teeth: 37)

10. Parking brake
11. Rear coupling
12. Output gear (number of teeth: 55)
13. Spacer
14. Output shaft
15. Front coupling
10-200
23
200 Power train

Transfer
SEN03924-01
Input shaft
Unit: mm
No.
Check item
Clearance between input shaft and

bearing (front)
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
60
+0.012
0.007
0
0.012
0.024
0.007
Clearance between input shaft

bearing and cage (front)
95
0
0.013
+0.016
0.006
0.006
0.029

bearing (middle)
50
+0.011
0.005
0
0.012
0.023
0.005

bearing and ring gear (middle)
80
0
0.013
+0.013
0.006
0.006
0.026

bearing (rear)
50
+0.011
0.005
0
0.012
0.023
0.005

bearing and carrier (rear)
80
0
0.013
+0.013
0.006
0.006
0.026
Clearance between press fitting

shaft and bearing
55
+0.039
+0.020
0
0.015
0.054
0.020
Clearance between press fitting

shaft bearing and motor 1 gear
100
0
0.018
0.016
0.038
0.038
0.002
Clearance between piston and

spacer
177
0.085
0.125
+0.040
0
0.085
0.165
10 Clearance between piston and cage
222
0.550
0.650
+0.046
0
0.550
0.696
between clutch housing

11 Clearance
and front case
200
+0.061
+0.015
+0.046
0
0.061
0.031
10-200
24
Replace
200 Power train

Transfer
SEN03924-01
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
1.7
0.05
1.6
Strain on separator plate
0.05
0.15
Thickness of friction plate
2.2
0.08
1.8
Strain on friction plate
0.02
0.25
1,147 N
{117 kg}
115 N
{11.7 kg}
918 N
{94 kg}
Inside diameter of seal ring contact

surface
25
+0.021
0
25.1
Width of seal ring groove
2.5
+0.15
+0.10
2.7
Width of seal ring
2.5
0.01
0.03
2.3
Thickness of seal ring
1.2
0.1
1.05

surface
90
+0.035
0
90.1
+0.15
+0.10
3.3
Width of seal ring
0.01
0.03
2.7
3.7
0.12
3.55

surface
120
+0.022
0
120.5
4.5
+0.1
0
5.0
Width of seal ring
4.36
0
0.1
3.9
0.1
2.7
Thickness of separator plate
12
13
of wave spring
14 Load
(height: 2.2 mm)
15
16
17

between motor 1 gear and
18 Backlash
output gear
clearance of planetary gear
Side
(on both sides)
Replace
0.190 0.465
0.35 0.80
10-200
25
SEN03924-01
200 Power train

Transfer
Output shaft
10-200
26
200 Power train

Transfer
SEN03924-01
Unit: mm
No.
Check item
Clearance between output shaft
and bearing (front)
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
60
+0.030
+0.011
0
0.015
0.045
0.011

bearing and cage (front)
110
0
0.018
0.015
0.040
0.040
0.003

and bearing (rear)
65
+0.030
+0.011
0
0.015
0.045
0.011

bearing and rear case (rear)
120
0
0.018
0.015
0.040
0.040
0.003
Clearance between oil seal and

cage (front)
100
+0.170
+0.080
+0.054
0
0.170
0.026
Clearance between dust seal and

cage (front)
100
+0.400
+0.200
+0.054
0
0.400
0.146

cage (rear)
100
+0.170
+0.080
+0.054
0
0.170
0.026
Clearance between dust seal and

cage (rear)
100
+0.400
+0.200
+0.054
0
0.400
0.146

and spacer
60
0
0.030
+0.030
0
0
0.060
diameter of coupling oil

10 Outside
seal contact surface (front)
diameter of coupling oil
11 Outside
seal contact surface (rear)
between cage and front
12 Clearance
case
rotational torque of output
13 Free
shaft
Standard size
Tolerance
Repair limit
75
0
0.074
74.8
75
0
0.074
74.8
Standard size
Standard clearance
Clearance limit
0.7
0.1 1.3
Replace
Adjust with shims
3.9 5.9 Nm {0.4 0.6 kgm}
10-200
27
SEN03924-01
10-200
28
200 Power train

Transfer
200 Power train

Transfer
SEN03924-01
1. HST motor 2
2. Motor 2 gear (number of teeth: 50)
3. Strainer
4. Drain plug
Unit: mm
No.
Check item

bearing

bearing and cage
Backlash between motor 2 gear and

output gear
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
65
+0.035
+0.013
0
0.015
0.050
0.013
120
0
0.015
+0.022
0.013
0.013
0.037
Replace
0.190 0.465
10-200
29
200 Power train

Transfer
SEN03924-01
Outline
q
The transfer is equipped with 2 HST motors. It
selects a gear speed out of 1st - 4th speed
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.
Operation of clutch
Clutch is "engaged" (fixed)
Relation between transfer clutch and transfer

clutch pressure at respective speed ranges
Speed
range
Transfer clutch
Transfer clutch pressure
1st
Engaged
OFF
2nd
Engaged
OFF
3rd
Travel speed Travel speed Travel speed Travel speed

0 A km/h A 18.7 km/h 0 A km/h A 18.7 km/h
4th
Travel speed Travel speed Travel speed Travel speed

0 A km/h A 38 km/h 0 A km/h A 38 km/h
Engaged
Engaged
Disengaged
Disengaged
OFF
OFF
ON
ON
*1: The travel speeds listed above are the ones when the tires
of the size 20.5-25 are worn. And value A varies depending
on the opening ratio of the accelerator pedal.
Relationship between accelerator pedal angle

and travel speed (A) for starting transfer clutch
switching modulation
Transfer clutch
Clutch is "disengaged" (released)
Accelerator pedal angle (%)

0 65
65 90
90 100
Engaged o
Disengaged (B)
8 km/h
8 10 km/h
10 km/h
Disengaged o
Engaged (C)
7 km/h
7 9 km/h
9 km/h
10-200
30
As the oil from the clutch solenoid valve is cut

off, piston (2) is pushed back in the right direction by the repulsive force of spring (1).
Piston (2) compresses plates (3) and discs (4)
and the rotation of discs (4) is stopped by the
frictional force.
As the internal teeth of disc (4) are meshed
with the external teeth of ring gear (5), ring
gear (5) is fixed.
The oil from the clutch solenoid valve is pressure-fed to the back side of piston (2), and
pushes piston (2) in the left direction by compressing spring (1).
Plates (3) and discs (4) are released from the
frictional force, setting ring gear (5) to the neutral position.
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.
200 Power train

Transfer
SEN03924-01
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)
O
Input shaft (4)
O
Sun gear (5)
O
Planetary pinion (6)
O
Carrier (7)
O
Motor 1 gear (8)
O
Output gear (10)
O
Output shaft (11)

O
O
O
O
O
O
O
O
O
Motor 2 gear (9)
O
i
10-200
31
SEN03924-01
200 Power train

Transfer
High speed mode
Transfer clutch (1) is released and, since HST motor 1 (2) stops, it transmits power of HST motor 2 (3) alone.
O
Motor 2 gear (9)
O
Output gear (10)
O
Output shaft (11)
10-200
32
200 Power train

Clutch solenoid valve
SEN03924-01
Clutch solenoid valve
P: From HST charge pump

A: To transfer clutch
T: To drain
2. Plunger
3. Coil
4. Push pin
5. Spring
6. Spool
7. Body
Operation
q
When the current value of input signal is large,
the transfer clutch drains oil pressure.
q
As the current value of input signal becomes
smaller, oil pressure of the transfer clutch goes
higher inversely proportional to the current
value.
q
If the current value of input signal is further
lowered until the oil pressure of the transfer
clutch reaches the oil pressure at which oil is
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 further decreased.
10-200
33
SEN03924-01
200 Power train

Axle
Axle
Front axle
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
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
200 Power train

Axle
SEN03924-01
Rear axle
1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
6. Coupling
7. Oil filler port and level plug
8. Drain plug
9. Brake oil port
10. Air bleeder
10-200
35
SEN03924-01
200 Power train

Differential
Differential
Front differential
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
200 Power train

Differential
SEN03924-01
Unit: mm
No.
Check item
Starting torque of bevel gear
Thickness of pinion washer
Criteria
Remedy
6.3 21.1 Nm {0.64 2.15 kgm} (outside of bevel gear)
Adjust
Standard size
Tolerance
Repair limit
0.08
2.8
0.05
3.8
Thickness of side gear washer
of shim in differential
10 Thickness
side bearing carrier (one side)
0.30 1.25
11 Backlash of bevel gear
0.20 0.33
Adjust
play of pinion
12 End
(or starting torque)
0 0.165
(0 65 N {0 6.5 kg} (at cage bolt hole))
Replace
1.07 0.33
Adjust
13 Thickness
housing and cage assembly
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
of differential
14 Clearance
Outer race
side bearing
120
0
0.020
0.041
0.076
0.076
0.021
Inner race
75
+0.051
+0.032
0
0.015
0.066
0.032
Outer race
140
0
0.018
0.054
0.082
0.082
0.036
Inner race
65
+0.039
+0.020
0
0.015
0.054
0.020
Clearance of bearing on Outer race

16 pinion shaft coupling
side
Inner race
120
0
0.015
0.041
0.076
0.076
0.026
55
+0.039
+0.020
0
0.015
0.054
0.020
28
0.06
0.11
+0.10
+0.05
0.11
0.21
268.5
0.110
0.191
+0.081
0
0.110
0.272
247
0.100
0.172
+0.072
0
0.100
0.244
Outer race
110
0
0.015
0
0.035
0.035
0.015
Inner race
50
+0.021
+0.002
0
0.012
0.033
0.002
of bearing on
15 Clearance
pinion shaft gear side
between pinion gear and

17 Clearance
spider
Clearance in installation position of
18 differential housing piston

(between housing and piston)
19 bearing carrier piston

(between piston and carrier)
Clearance between
20 drive shaft and cage
bearing
Replace
Replace
10-200
37
SEN03924-01
Rear differential
200 Power train

Differential

2. Shaft
4. Sun gear shaft
5. Bevel pinion (number of teeth: 10)
10-200
38
200 Power train

Differential
SEN03924-01
Unit: mm
No.
Check item
Starting torque of bevel gear
Thickness of pinion washer
Criteria
Remedy
6.3 21.1 Nm {0.64 2.15 kgm} (outside of bevel gear)
Adjust
Standard size
Tolerance
Repair limit
0.08
2.8
0.05
3.8
Thickness of side gear washer
10 Thickness
side bearing carrier (one side)
0.30 1.25
11 Backlash of bevel gear
0.20 0.33
Adjust
play of pinion
12 End
(or starting torque)
0 0.165
(0 65 N {0 6.5 kg} (at cage bolt hole))
Replace
1.07 0.33
Adjust
13 Thickness
housing and cage assembly
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
of differential
14 Clearance
Outer race
side bearing
120
0
0.020
0.041
0.076
0.076
0.021
Inner race
75
+0.051
+0.032
0
0.015
0.066
0.032
Outer race
140
0
0.018
0.048
0.088
0.088
0.030
Inner race
65
+0.039
+0.020
0
0.015
0.054
0.020
Clearance of bearing on Outer race

16 pinion shaft coupling
side
Inner race
120
0
0.015
0.041
0.076
0.076
0.026
55
+0.039
+0.020
0
0.015
0.054
0.020
28
0.06
0.11
+0.10
+0.05
0.11
0.21
268.5
0.110
0.191
+0.081
0
0.110
0.272
247
0.100
0.172
+0.072
0
0.100
0.244
of bearing on
15 Clearance
pinion shaft gear side
between pinion gear and

17 Clearance
spider
18 differential housing piston

(between housing and piston)
19 bearing carrier piston

(between piston and carrier)
Replace
Replace
10-200
39
200 Power train

Differential
SEN03924-01
Outline
While machine is traveling straight

the front and rear axles through the torque
converter, transmission and drive shaft.
In each axle, the direction of the power is
changed by 90 and the speed is reduced by
bevel pinion (1) and bevel gear (5). Then, the
power is transmitted through pinion (4) to sun
gear shafts (2).
Speed of the power transmitted to the sun gear
is further reduced by the final drive of the planetary gear type, and then transmitted to the
axle shafts and wheels.
While machine is turning
10-200
40
While the machine is traveling straight, the

right and left wheels rotate at the same speed.
Accordingly, pinion (4) in the differential
assembly does not rotate and the power of carrier (6) is transmitted through pinion (4) and
side gear (3) to right and left sun gear shafts
(2) evenly.
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 difference in rotation speed between the right and
left wheels.
200 Power train

Torque proportioning differential
SEN03924-01

Outline
Operation
Straight travel (When the road resistances
under both tires are the same)
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 distance (b) to the meshing point of right side
gear (3) are the same.
Accordingly, left traction force (TL) and right
traction force (TR) are balanced.
Travel on soft ground (When the road resistances under both tires are different)
A 4-wheel-drive wheel loader, as a construction 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.
Pinion (4) of this differential has an odd number of teeth. The meshing points of pinion (4)
and side gears (3) change according to the difference of the road resistance. Consequently,
the traction forces of the tires on both sides
change.
When the tires slip on soft ground, the side

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.
If left side gear (7) turns forward a little, distance (a) from the pinion to the meshing point
of the left side gear becomes longer than distance (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.
10-200
41
SEN03924-01
q
200 Power train

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%.
The lives of the tires are lengthened 20 - 30%
and the working capacity is increased by the
above effect.
10-200
42
200 Power train

SEN03924-01
10-200
43
SEN03924-01
Limited slip differential
200 Power train

(If equipped)
1. Plate
2. Disc
4. Washer
6. Bevel pinion
7. Shaft
8. Pressure ring
10. Case
10-200
44
200 Power train

SEN03924-01
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Tolerance
Repair limit
0.02
2.9
+0.04
0.03
2.45
0.05
1.8
11 Thickness of plate
3.1
12 Thickness of disc
2.5
2
13 Thicknesses of washer
2.1
between disc and plate
14 Clearance
(total clearance on both sides)
play of side gear in axial
15 End
direction (one side)
0.13 0.35
16 Backlash of case and plate
0.1 0.6
17 Backlash of side gear and disc

between spider and
18 Clearance
differential pinion
0.13 0.36
Standard
size
28
Replace
0.2 0.6
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
0.11
0.16
+0.05
0
0.11
0.21
10-200
45
200 Power train

SEN03924-01
Operation of limited slip differential
q
The power from the transmission is transmitted
through bevel gear (9), case (10), pressure
ring (8), shaft (7), pinion (3) and side gear (5),
and then divided to the right and left shafts.
q
The brake unit consisting of disc (2) and plate
(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 operation of the differential is restricted.
While machine is traveling straight

When the drive forces of the right and left
wheels are balanced
[When the road conditions (coefficient of friction)
under both wheels and the wheel loads are even,
and the center of load is at the center of the bucket]
Mechanism of generation of braking torque by

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

being provided on the surfaces of pressure
rings (8) that are facing each other.
The power (= torque) transmitted from pressure rings (8) to shaft (7) is transmitted on the
cam surfaces. Force (Fa) to separate pressure
rings (8) from each other is generated by inclination of the cam surfaces in proportion to the
transmitted torque.
Separating load (Fa) acts on the brake on the
back side of each side gear (5) to generate
braking torque.
10-200
46
The power from the transmission is distributed

evenly by the differential gears to the right and
left. Under this condition, the slip limits of the
right and left wheels are the same. Accordingly, even if the power from the transmission
may exceed the slip limits, both wheels slip
and the differential does not work.
No load is applied to the brake on the back
side of the side gear.
200 Power train

When the drive forces of the right and left

wheels are unbalanced
[When the road conditions (coefficient of friction)
under both wheels and the wheel loads are uneven,
and either wheel slips more easily]
Example 1. When either wheel is on soft ground
in digging work
Example 2. When either wheel is on snow and
the other one is on asphalt in snow
removing work
Example 3. When the right and left wheel loads
are unbalanced in travel on a slope
SEN03924-01
Difference in wheel drive force by type of differentials when either wheel slipped
Wheel drive force
(drive force of slipping wheel is 1)
Slipping wheel Locked wheel
Total (ratio)
Limited slip
differential
(if equipped)
2.64
3.64 (1.53)
Torque
proportioning
differential
(standard)
1.38
2.38 (1)
Conventional
differential
2 (0.84)

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 proportioning 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 differential.
While machine is turning
The power from the transmission is evenly

divided between the right and left by the differential gear. If, however, the divided drive force
exceeds the wheel slip limit of the slip side,
surplus of the driving force is transmitted to the
opposite side (lock side) brake through the
brake and case on the gear back side. Then
the power is distributed to the lock side wheel.
The differential starts working only as the surplus portion of the drive force has exceeded
the braking force.
The same gears as that for the conventional

differential are employed for the limited slip differential. Thus, they allow to smoothly generate a difference in rotation speed between the
outer and inner wheels that is necessary for
tuning.
10-200
47
SEN03924-01
200 Power train

Final drive
Final drive
Front final drive
1. Planetary gear (number of teeth: 26)

2. Planetary carrier
3. Axle shaft
5. Sun gear shaft (number of teeth: 15)
10-200
48
200 Power train

Final drive
SEN03924-01
Rear final drive
1. Planetary gear (number of teeth: 26)

2. Planetary carrier
3. Axle shaft
5. Sun gear shaft (number of teeth: 15)
10-200
49
200 Power train

Final drive
SEN03924-01
Unit: mm
No.
Check item
Criteria
Clearance between planetary gear

bearing and shaft
Clearance between axle housing

and ring gear

housing
Press fitting part of axle

shaft seal
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
33.338
+0.025
+0.013
+0.013
0
0.025
0
316
+0.10
+0.03
+0.10
+0.04
0.06
+0.07
Max. 0.2
Adjust
Housing
155
+0.4
+0.2
+0.063
0
0.4
0.137
Shaft
115
0
0.054
0.2
0.4
0.4
0.146
Clearance of press
10 fitting part of axle
housing bearing
Outer race
152.4
+0.025
0
0.012
0.052
0.077
0.012
Inner race
92.075
+0.073
+0.051
+0.025
0
0.073
0.026
Clearance of press
11 fitting part of axle
housing bearing
Outer race
130
0
0.025
0.038
0.078
0.078
0.013
Inner race
85
+0.035
+0.013
0
0.020
0.055
0.013
12 End play of axle shaft

13 Clearance of guide pin
Replace
0 0.1
12
+0.025
+0.007
+0.207
+0.145
Replace
Adjust
0.120
0.200
Replace
Starting force of axle housing, see "Disassembly and assembly of axle housing" in Disassembly and
assembly.
10-200
50
200 Power train

Final drive
SEN03924-01
Outline
a
q
q
q
The figure shows the front axle.

The final drive finally reduces speed of the
power from the engine to increase the drive
force.
Ring gear (4) is press fitted to the axle housing
and fixed with the pin.
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.
10-200
51
SEN03924-01

2009 KOMATSU
All Rights Reserved
10-200
52
SEN03925-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up

10
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
10-300
SEN03925-01
10-300
300 Steering system
300 Steering system

Steering piping diagram
SEN03925-01
Steering piping diagram
1. Steering cylinder (right)

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

Steering column
SEN03925-01
Steering column
1. Steering wheel
2. Steering column
3. Orbit-roll valve
4. Steering tilt lock lever
Unit: mm
No.
5
Check item
Clearance between steering shaft
and column bushing
Criteria
Standard
size
19
10-300
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
0
0.08
+0.15
+0.05
0.05
0.23
0.4
Replace
300 Steering system

Priority valve
SEN03925-01
Priority valve
P: From steering pump

CF: To Orbit-roll valve
EF: To work equipment control valve
LS: From Orbit-roll valve

T: To hydraulic tank
1. Relief valve body

2. Spring seat
3. Spring
4. Poppet
5. Seat
6. Screen
7. Plug
8. Valve body
9. Spool
10. Spring
11. Plug
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Free length
Installed
length
Installed
load
Free length
Installed
load
63.4
47.6
187 N
{19.1 kg}
63.4 1
187 14.7 N
{19.1 1.5
kg}
31
26.9
146 N
{14.9 kg}
146 14.7 N
{14.9 1.5
kg}
12 Control spring
13 Relief spring
Repair limit
Replace
10-300
300 Steering system

Priority valve
SEN03925-01
Outline
q
The priority valve is installed between the
steering pump and Orbit-roll valve and work
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}
Operation
When steering wheel is at "neutral" position
10-300
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.
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).
The oil that flew to chamber (P) through orifice
(m) of spool (3) pushes spool (3) in the right
direction by compressing spring (4).
Port (M) and port (Q) are opened and port (M)
and port (N) are almost closed to stabilize
spool (3).
Most of the oil from the pump flows to the work
equipment circuit through port (Q).
300 Steering system

Priority valve
When steering wheel is "turned left"
Turning the steering wheel left changes the

angle between the sleeve and spool on the
Orbit-roll valve, switching flow of the oil. (see
"Orbit-roll valve".)
Part of the oil from the pump that has flown to
port (A) is then conducted to the R.H. steering
cylinder through port (B) and Gerotor, and the
remaining portion of the oil flows to chamber
(R) through orifice (b) and port (J).
Change in the angle between the sleeve and
spool on the Orbit-roll valve generates a difference pressure between the oil pressure up to
port (A) and that after port (B).
Spool (3) stabilizes at a position where the difference pressure between that of up to port (A)
and after port (B) [chamber (P) pressure chamber (R) pressure] is balanced with the
repulsive force of spring (4).
The ratio of diversion is determined by the displacement 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.
SEN03925-01
When steering cylinder is at stroke end
Trying to continuously turn the steering wheel

after the steering cylinder has reached the
stroke end increases oil pressure in port (S).
As the oil pressure in port (S) goes beyond the
set pressure of relief valve (10), the relief valve
(10) releases the oil pressure in port (S) to the
hydraulic tank through port (T).
It generates differential pressure before and
after orifice (r), breaking down the balance
between the difference pressure up to port (A)
and after port (B) and the repulsive force of
spring (4). As a result, oil pressure up to port
(A) becomes relatively higher.
As port (A) oil pressure is increased, oil in
chamber (P) pushes spool (3) in the right direction by compressing spring (4).
Port (M) and port (N) are almost closed, and
port (M) and port (N) are nearly fully opened to
stabilize spool (3).
10-300
300 Steering system

Orbit-roll valve
SEN03925-01
Orbit-roll valve
P: From steering pump

L: To steering cylinder
R: To steering cylinder
LS: To priority valve

1. Gland
2. Valve body
3. Check valve
4. Gerotor
5. Spacer
6. Cover
7. Spacer
8. Drive shaft
9. Sleeve
10. Spool
11. Center pin
12. Centering spring
13. Anti-cavitation valve
14. Overload relief valve
10-300
300 Steering system

Orbit-roll valve
Outline
The Orbit-roll valve is connected to the drive

shaft of the steering column. It changes the oil
flow from the steering pump to the right or left
steering cylinder to decide the travel direction
of the machine.
The Orbit-roll valve is roughly divided into
spool (9) and sleeve (8) that have rotary type
direction selecting function and Gerotor (5)
(combination of rotor (5a) and stator (5b)) that
operates as a hydraulic motor during the normal steering operation and as a hand pump
(the steering wheel's operating effort becomes
too high to operate it actually) when the oil is
not supplied because of a trouble of the steering pump or engine.
SEN03925-01
Structure
Top (A) of spool (9) is connected to the drive

shaft of the steering column and further connected to sleeve (8) through center pin (7)
(which is not in contact with spool (9) while the
steering wheel is at "neutral") and centering
spring (2).
Top (B) of drive shaft (3) is engaged with center pin (7) and united with sleeve (8) and the
bottom is engaged with the spline of rotor (5a)
of the Gerotor (5).
4 ports are provided on valve body (4). Each
port is respectively connected to the pump circuit, tank circuit, L.H. steering circuit and R.H.
steering circuit. And the ports of the pump side
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.
10-300
SEN03925-01
300 Steering system

Orbit-roll valve
Operation
When steering wheel is at "neutral" position
10-300
10
300 Steering system

Orbit-roll valve
q
q
q
SEN03925-01
When the steering wheel is at "neutral" position, 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.
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).
Orifice (b) of port (J) to the priority valve is connected to vertical groove (B) on spool (9).
Port (K) of sleeve (8) is connected to vertical
groove (M) and port (L) on spool (9).
Due to connection and disconnection of the
ports and vertical grooves, the oil in the priority
valve being set to the pilot pressure is conducted through port (J), orifice (b), vertical
groove (M) and port (K), then drained from port
(L) to the hydraulic tank.
10-300
11
SEN03925-01
300 Steering system

Orbit-roll valve
When steering wheel is "turned left"
10-300
12
300 Steering system

Orbit-roll valve
As the steering wheel is "turned left", spool (9)

being connected to the drive shaft of the steering column is rotated counterclockwise.
Since spool (9) and sleeve (8) are connected
by centering spring(2), spool (9) compresses
centering spring (2).
An angular displacement corresponding to the
amount of compression of centering spring (2)
is generated between spool (9) and sleeve (8).
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.
Although the connection between vertical
groove (B) and orifice (b) of port (J) to the priority valve is maintained, port (K) of sleeve (8)
starts gradually closing vertical groove (M) and
port (L).
Port (F) of the R.H. steering circuit is connected to vertical groove (D) at the same time
as port (A) and vertical groove (B) are connected.
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).
Oil pressure of vertical groove (M) is transmitted to port (J) through orifice (b), then supplied
from port (J) as the pilot pressure of the priority
valve.
The oil from the R.H. steering cylinder head is
drained to the hydraulic tank through port (F),
vertical groove (D) and port (H).
SEN03925-01
When steering wheel is at "stop" position
q
As operation of the steering wheel is stopped,
angular displacement between spool (9) and
sleeve (8) disappears and the steering wheel
is returned to the neutral position by the repulsive force of centering spring (2).
10-300
13
300 Steering system

Orbit-roll valve
SEN03925-01
Connection of hand pump and sleeve
Above figure shows the suction and discharge

ports (P) of the Gerotor and connections with
the sleeve ports.
If the steering wheel is turned to the right, ports
(a), (c), (e), (g), (i), and (k) will be connected to
the pump side by the vertical grooves of the
spool. Likewise, ports (b), (d), (f), (h), (j), and (l)
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).
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
The internal gear of the Gerotor advances by 1

tooth with every 1/7 turn of the steering wheel
and discharges the oil from the pump according to the steering angle of the steering wheel.
Accordingly, the discharge amount varies in
proportion to the steering angle of the steering
wheel.
300 Steering system

Orbit-roll valve
SEN03925-01
Role of centering spring
Centering spring (2) is composed of 4 Xshaped leaf springs and 2 flat leaf springs and
installed between spool (9) and sleeve (8) as
shown in the figure.
If the steering wheel is turned, spool (9) compresses centering spring (2) and angular displacement (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 reaction force of centering spring (2) by angular
displacement (a) of spool (9) and sleeve (8) to
return the steering wheel to the "neutral" position.
10-300
15
SEN03925-01
Cushion valve
A: From steering cylinder left turning port

AS: From steering cylinder left turning port
B: From steering cylinder right turning port
BS: From steering cylinder right turning port
1. Valve seat
2. Valve body
3. Spring
4. Poppet
5. Orifice
6. Plug
7. Spring
8. Spool
9. Plug
10. Spring
11. Poppet
10-300
16
300 Steering system

Cushion valve
Outline
q
If sudden increase or bouncing occurs in oil
pressure of the steering cylinder circuit, this
valve mitigates the impacts by releasing the
highly pressurized oil to instantly to other line.
Function
q
As highly pressurized oil rushed into port (A), it
compresses spring (3) and opens poppet (4) of
port (A) side, then flows through the center
groove of spool (8) up to port (B) opening poppet (11) of port (B) side.
q
At the same time, the highly pressurized oil
flows to the pressure chamber of plug (6)
through orifice (5) of port (A) side. Then overcoming the port (B) side pressure and repulsive 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 functions 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.
300 Steering system

Steering cylinder
SEN03925-01
Steering cylinder
Unit: mm
No.
Check item
Clearance between bushing in
cylinder rod frame connecting part
and mounting pin
Clearance between bushing in

cylinder bottom frame connecting
part and mounting pin
Connecting part of steering cylinder

and front frame
Connecting part of steering cylinder

and rear frame
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
40
0
0.025
+0.180
+0.042
0.042
0.205
40
0
0.025
+0.180
+0.042
0.042
0.205
Width of boss
Width of hinge
Standard (a + b) clearance
50
53
Max. 0.5
(after shim is adjusted)
50
53
Max. 0.5
(after shim is adjusted)
Replace
10-300
17
300 Steering system

Steering cylinder
SEN03925-01
Unit: mm
No.
Check item
Criteria
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
40
0.025
0.064
+0.121
0.005
0.020
0.185
0.485
Clearance between piston rod

supporting shaft and bushing
40
0
0.025
+0.180
+0.042
0.042
0.205
1.0
Clearance between cylinder bottom

supporting shaft and bushing
40
0
0.025
+0.180
+0.042
0.042
0.205
1.0
Clearance between piston rod and

bushing
10-300
18
Standard
size
Tolerance
Replace pin and

bushing
300 Steering system

Emergency steering piping diagram
SEN03925-01
Emergency steering piping diagram
(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)
10-300
19
300 Steering system

Emergency steering valve
SEN03925-01
(If equipped)
PP: From steering pump

A: To HST motor 2 port A
B: To HST motor 2 port B
Y: To Orbit-roll valve
S: From hydraulic tank
G: To pressure switch
10-300
20
1. Check valve body

2. Check valve
3. Valve body
4. Pressure reducing valve
5. Selector valve
300 Steering system

SEN03925-01
Operation
When engine and steering pump are normal
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.
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.
10-300
21
SEN03925-01
300 Steering system

When engine or steering pump is abnormal
q
q
If, during travel, the steering pump fails to supply 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 repulsive force of spring (2).
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).
De-pressurized oil flows through port (Y) to the
Orbit-roll valve, enabling the steering.
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).
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
300 Steering system

Steering relief valve
SEN03925-01
Steering relief valve
(If equipped)
P1: From steering pump

P2: From emergency steering pump
T: Drain
S1: Steering pump oil pressure switch
S3: Emergency steering oil pressure switch
Outline
q
The steering relief valve is installed to the right
side of the transmission and used to hold the
steering oil pressure to the set pressure.
Set pressure: 1.96 MPa {20 kg/cm2}
(cracking pressure at 0.5 l/min)
1. Block
2. Relief valve
3. Orifice
10-300
23
SEN03925-01

2009 KOMATSU
All Rights Reserved
10-300
24
SEN03926-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up

10
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
10-400
SEN03926-00
10-400
400 Brake system
400 Brake system

Brake piping diagram
SEN03926-00
Brake piping diagram
1. Hydraulic tank
2. Brake valve
4. Rear brake
5. Accumulator (for front side)
6. Accumulator (for rear side)
7. Charge valve
8. Strainer
9. Slack adjuster (for front left side)
10. Front brake
11. Slack adjuster (for front right side)
12. Slack adjuster (for rear right side)
13. Slack adjuster (for rear left side)
10-400
SEN03926-00
Charge valve
10-400
400 Brake system

Charge valve
400 Brake system

Charge valve
SEN03926-00
P: From brake and cooling fan pump

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
No.
Check item
Clearance between inverse shuttle

valve and body
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
12
0.006
0.014
+0.011
0
0.006
0.025
0.029
Clearance between plunger and

body
0.005
0.012
+0.009
0
0.005
0.021
0.024
Clearance between unload valve

and body
18
0.006
0.017
+0.011
0
0.006
0.028
0.032
Standard size
Repair limit
Installed
length
Installed
load
21.6
relief valve return spring
11 Unload
(inside)
Free length
Installed
load
18.3
9.8 N
{1.0 kg}
8.3 N
{0.85 kg}
35.9
30.0
188 N
{19.2 kg}
160 N
{16.3 kg}
relief valve return spring

12 Unload
(outside)
39.8
27.5
137 N
{14.0 kg}
116 N
{11.8 kg}
13 Unload valve return spring
51.6
45.0
49 N
{5.0 kg}
42 N
{4.3 kg}
14 Check valve return spring
11.5
9.0
4.9 N
{0.5 kg}
4.2 N
{0.43 kg}
10 Inverse shuttle valve return spring
Free length
Replace
Function
q
The charge valve maintains the oil pressure
from the pump to the set pressure and accumulates it in the accumulator.
q
If the oil pressure from the pump goes beyond
the relief valve s et pres sur e, this valve
releases the oil pressure to the drain circuit in
order to reduce the load to the pump.
10-400
400 Brake system

Charge valve
SEN03926-00
Operation
When oil is not supplied to accumulator
(cut-out state)
Plunger (1) is moved in the left direction by the

accumulator pressure, and maintains unload
relief valve (2) being pushed open.
The oil in the spring chamber of unload valve
(3) is drained to the hydraulic tank through port
(F), unload relief valve (2) and port (T).
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).
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).
When oil is supplied to accumulator

1. Cut-in state
q
q
10-400
As the accumulator pressure goes low, pressure on port (E) goes low, allowing plunger (1)
to move in the right direction and unload relief
valve (2) to close the drain circuit.
Since the oil pressure in port (F) and the spring
chamber of unload valve (3) increases, unload
valve (3) moves in the right direction.
Port (C) and port (B) are opened, conducting
the oil from the pump to port (B).
As oil pressure in port (B) increases beyond
the set pressure of check valve (4), check
valve opens, allowing the oil to be supplied to
the accumulator through port (E). The pressure
for supplying oil to the accumulator depends
on the set pressure of check valve (4).
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).
Inverse shuttle valve (5) supplies precedence
to the accumulator of lower pressure when
supplying oil.
400 Brake system

Charge valve
2.
When pressure reaches cut-out pressure
As pressure in port (F) reaches the set pressure (cut-out pressure of unload relief valve
(2)), oil in the spring chamber of unload valve
(3) is drained to the hydraulic tank through port
(F), unload relief valve (2) and port (T).
Plunger (1) is moved in the left direction by the
accumulator pressure, and maintains unload
relief valve (2) being pushed open.
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).
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).
SEN03926-00
When the oil pressure from the pump went
beyond the set pressure
As oil pressure in chamber (B) reaches the set

pressure of relief valve (6), relief valve (6) is
opened to drain the oil from the pump to the
hydraulic tank through port (T).
Above process protects the brake circuit by
restricting its maximum pressure.
10-400
400 Brake system

Brake valve
SEN03926-00
Brake valve
P1: From HST pump

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

6. Brake valve spool (for front)
7. Brake valve body (for front)
Unit: mm
No.
8
Check item
Clearance between inching valve
spool and body
Clearance between inching valve
guide and body
between inching valve

10 Clearance
spool and guide
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
22.4
0.022
0.053
+0.033
0
0.020
0.086
0.096
22.4
0.022
0.053
+0.033
0
0.020
0.086
0.096
12
0.050
0.093
+0.050
0
0.050
0.143
0.157
Standard size
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
34.7
16.7
24.5 N
{2.5 kg}
20.8 N
{2.1 kg}
12 Brake valve control spring
35.6
24.0
113 N
{11.5 kg}
96 N
{9.8 kg}
13 Inching valve return spring
50.0
49.5
19.6 N
{2.0 kg}
16.7 N
{1.7 kg}
14 Brake valve return spring
114.9
52.4
147 N
{15.0 kg}
125 N
{12.7 kg}
11 Inching valve control spring
10-400
Replace
400 Brake system

Brake valve
SEN03926-00
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, operating 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
Brake pedal (1) pressing effort is transmitted to

spool (5) through rod (2), spool (3) and spring
(4).
As spool (5) is pushed in the right direction,
port (Ta) is closed and the oil from the pump
activates the rear brake after being conducted
through the accumulator, port (PA), port (A)
and rear brake piston.
As spool (5) is pushed in the right direction,
spool (6) is also pushed in the right direction,
closing port (Tb). The oil from the pump flows
through the accumulator, port (PB) and port (B)
to the front brake piston to activate the front
brake.
When brake of one side is operated

(when the other brake failed)
q
Even when only one side of the brakes
remains operable due to, for instance, oil leak
on the front or rear brake system, brake pedal
(1) pressing effort moves in the right direction
after being transmitted mechanically through
spool (5) and spool (6).
q
Oil from the pump is conducted normally to the
brake piston of the healthy system to enable
stopping the machine as needed in order to
ensure safety.
10-400
SEN03926-00
400 Brake system

Brake valve
Balancing operation
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.
Since port (Ta) remains closed, the oil conducted to the brake piston is retained and the
brake remains operable.
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 chamber (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.
Since port (Tb) remains closed, the oil conducted to the brake piston is retained and the
brake remains operable.
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].
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
brake cir cuit and the front br ake circuit
becomes equal to that from the pump.
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
400 Brake system

Brake valve
SEN03926-00
When brake pedal is released
q
q
Releasing brake pedal (1) releases the pedal

pressing effort being applied to spool (5).
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.
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.
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.
Oil in the front brake piston is drained to the
hydraulic tank through port (B) and port (Tb),
releasing the front brake.
10-400
11
SEN03926-00
Inching valve
P1: From HST pump port Y

T2: To steering pump (suction side)
1. Brake pedal
2. Brake valve
3. Spool
4. Body
10-400
12
400 Brake system

Inching valve
Outline
q
The inching valve, which is contained in brake
valve (2), reduces the control oil pressure of
the HST circuit responding to stroke (S) of
spool (3) in order to reduce the capacity of the
HST pump.
400 Brake system

Accumulator (for brake)
SEN03926-00
Accumulator (for brake)
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 hydraulic pump and secures the braking force and
operability when the engine is stopped by utilizing its compressibility.
Specifications
Gas used
Nitrogen gas
Amount of gas (cc)
500
Charge pressure
(MPa {kg/cm2})
3.5 0.1 {35.7 1}

(at 20C)
Max. pressure used

(MPa {kg/cm2})
10 {102}
10-400
13
400 Brake system

Slack adjuster
SEN03926-00
Slack adjuster
A: From brake valve

B: To brake piston
1. Body
2. Check valve
3. Piston
Unit: mm
No.
4
Check item
Clearance between piston and
body
Clearance between check valve
and body
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
30
0.065
0.098
+0.052
0
0.065
0.150
0.163
10
0.013
0.028
+0.015
0
0.013
0.043
0.048
Standard size
Piston return spring
Check valve return spring
10-400
14
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
87.5
48.2
11.8 N
{1.2 kg}
9.8 N
{1.0 kg}
21.7
19.25
53.9 N
{5.5 kg}
46.1 N
{4.7 kg}
Replace
400 Brake system

Slack adjuster
SEN03926-00
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
The oil from the brake valve flows to port (A)

and moves piston (1) in the right direction to
activate the brake using the oil being amassed
between piston (1) and the brake piston.
The slack adjuster maintains the time lag up to
activation of the brake constant by operating
t he b r a k e u s i n g th e o i l b e i ng a m a s s e d
between piston (1) and the brake piston.
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.
When brake is released
The oil being stopped between piston (1) and

brake piston pushes back piston (1) in the left
direction, allowing the oil, equivalent in the volume to piston (1) move distance, to return to
the brake valve through port (A) then is drained
to the hydraulic tank.
10-400
15
SEN03926-00
400 Brake system

Brake
Brake
Front brake
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
400 Brake system

Brake
SEN03926-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
6.5
0.1
6.0
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.)
Standard size
Tolerance
Wear limit
20.1
0.1
0.3
Installed height
Installed load
Installed load
7.6
912 N
{93 kg}
730 N
{74 kg}
Thickness of brake disc
of disc contact surface of

12 Wear
brake outer ring
Standard size
of spring
13 Load
(when 2 pieces are piled)
Replace
Repair limit
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).
10-400
17
SEN03926-00
Rear brake
400 Brake system

Brake
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
400 Brake system

Brake
SEN03926-00
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
6.5
0.1
6.0
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.)
Standard size
Tolerance
Wear limit
20.1
0.1
0.3
Installed height
Installed load
Installed load
7.6
912 N
{93 kg}
730 N
{74 kg}
of disc contact surface of

12 Wear
brake outer ring
Standard size
of spring
13 Load
(when 2 pieces are piled)
Replace
Repair limit
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).
10-400
19
SEN03926-00
400 Brake system

Brake
Operation
When brake is operated
As the brake pedal is pressed, oil pressure (P)

being supplied through the hydraulic tank,
pump and brake charge valve to the brake cylinder 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
If the oil pressure is released, piston (2) is

returned to the original position by the returning force of spring (8) and clearance is made
between inner ring (3) and outer ring (5), and
disc (4) becomes free.
The linings stuck to disc (4) have cross
grooves on them. While disc (4) is rotating, oil
flows in those grooves to cool the linings.
10-400
20
400 Brake system

Parking brake control
SEN03926-00
Parking brake control
1. Parking brake lever

2. Parking brake lever bottom switch
3. Parking brake lever intermediate switch
4. Control cable
5. Transfer
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 operator'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", current 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 position.
10-400
21
400 Brake system

Parking brake
SEN03926-00
Parking brake
1. Lever
2. Housing
3. Ball
4. Piston
5. Plate
6. Disc
7. Wave spring
8. Output shaft
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Tolerance
Repair limit
2.6
0.06
2.5
Strain on plate
0.05
0.1
2.2
0.08
2.05
Strain on brake disc
0.02
0.25
1,010 N
{103 kg}
101 N
{10.3 kg}
858 N
{87.6 kg}
Thickness of plate
Replace
10
of wave spring
11 Load
(height: 2.2 mm)
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
400 Brake system

Parking brake
SEN03926-00
10-400
23
SEN03926-00

2008 KOMATSU
All Rights Reserved
10-400
24
SEN03927-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up


Axle mount and center hinge pin .................................................................................................................... 2
Tires ................................................................................................................................................................ 7
10-500
SEN03927-00
Axle mount and center hinge pin

a

The following drawing shows WA320-6.
10-500

1.
2.
3.
4.
5.
6.
7.
8.
9.
Front axle
Tension bolt
Rear axle
Frame lock bar
Front frame
Center hinge pin
Rear frame
Additional counterweight
Counterweight
SEN03927-00
Outline
q
Front axle (1) receives the force during work
directly. Thus, it is fixed directly to front fame
(5) with tension bolt (2).
q
Rear axle (3) is designed to sway at the center
of rear frame (7) so that each tire may contact
the ground surface even when the machine is
traveling on soft ground.
q
Front frame (5) and rear frame (7) are coupled
by the center hinge pin (6) with the bearing
between them. The right and left steering cylinders connect the front frame (5) and rear frame
(7). They adjust the bending angle or the turning radius of the frame according to move of
the cylinder.
10-500
SEN03927-00
10-500


SEN03927-00
Unit: mm
No.
1
Check item
Clearance between upper hinge pin
and rear frame
Criteria
Tolerance
Standard
size
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
75
0.030
0.076
+0.046
0
0.030
0.122

and spacer (small)
75
0.030
0.076
+0.250
0
0.030
0.326

and bearing
75
0.030
0.076
0
0.015
0.015
0.076

and spacer (large)
75
0.030
0.076
+0.026
0.020
0.010
0.102
Clearance between rear frame and

spacer (large)
90
0.010
0.040
+0.054
0
0.010
0.094
Clearance between front frame and

upper hinge bearing
120
0
0.020
0.030
0.076
0.076
0.010
Clearance between lower hinge pin

and rear frame bushing
75
0.030
0.076
+0.067
+0.027
0.057
0.143
Clearance between lower hinge pin

and bearing
75
0.030
0.076
0
0.015
0.015
0.076
Clearance between front frame and

lower hinge bearing
115
0
0.015
0.041
0.076
0.076
0.026
between rear frame and

10 Clearance
bushing
85
+0.089
+0.059
+0.054
0
0.089
0.005
of press fitting part of

11 Clearance
lower hinge pin seal
90
+0.280
+0.180
+0.054
0
0.280
0.126
of upper hinge spacer

12 Height
(small)
13 Height of upper hinge spacer (large)
Standard size
Tolerance
Repair limit
24.5
0.1
64.0
0.1
thickness of shim
14 Standard
between upper hinge and retainer
2.0
thickness of shim
15 Standard
between upper hinge and retainer
1.0
thickness of shim
16 Standard
between lower hinge and retainer
1.0
torque of upper hinge

17 Tightening
retainer mounting bolt
torque of lower hinge

18 Tightening
retainer mounting bolt
19.6 2.0 Nm {2.0 0.2 kgm} (when shim is adjusted)
Replace
Adjust
98 123 Nm {10.0 12.5 kgm} (final value)

19.6 2.0 Nm {2.0 0.2 kgm} (when shim is adjusted)
98 123 Nm {10.0 12.5 kgm} (final value)
10-500

SEN03927-00
Unit: mm
No.
Check item
Thickness of thrust plate
Thickness of thrust washer
Clearance between shaft and hole

on front support side
Clearance between shaft and hole

on rear support side
10-500
Criteria
Remedy
Standard size
Tolerance
Repair limit
22
0.5
+0.3
0.1
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
190
0.050
0.122
+0.472
0
0.050
0.594
170
0.005
0.124
+0.522
+0.050
0.055
0.646
Replace

Tires
SEN03927-00
Tires
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
The cords of carcass (1) are arranged at right
angles to the center line of tread (T) (radially).
q
Tread (T) is stabilized and protected by several
strong belts (2).
q
Side wall (W) and tread (T) are independent
from each other.
Structure
q
The cords of carcass (1) are arranged bias
from the center line of tread (T).
q
Side wall (W) and tread (T) are integral.
Ground contact characteristics

q
Even if the tire is deformed by a load, it does
not move uselessly in ground contact and uniform ground contact surface is secured stably.
Ground contact characteristics

q
If the tire is deformed by a load, the ground
contact surface is also deformed, leading to
wasteful moves. As a result, the ground contact surface becomes unstable.
Deformation characteristics
Only side wall (W) is deformed as load is
applied and tread (T) made of strong belts (2)
keeps stability independently.
Deformation characteristics
Side wall (W) which receives loads and tread
(T) move as one unit.
10-500
SEN03927-00

2008 KOMATSU
All Rights Reserved
10-500
SEN03928-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up

10

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
10-600
SEN03928-00
Work equipment hydraulic piping diagram

WA320-6
10-600

1.
2.
3.
4.
5.
6.
7.
8.

Bucket cylinder
Hydraulic tank
Lock valve
Oil cooler
Check valve
4-gear pump
Steering pump
Work equipment pump
9. Cut off valve
10. Accumulator (for ECSS) (if equipped)
11. Lift cylinder
12. ECSS valve (if equipped)
13. Accumulator (for PPC circuit)
SEN03928-00
Outline
q
The hydraulic system is consisted of the HST,
steering, work equipment, brake, cooling fan
and transfer lubrication circuit. The work equipment circuit controls move of the lift arm and
bucket.
q
The oil in hydraulic tank (3) is supplied to work
equipment control valve (1) by work equipment
pump of 4-gear pump (8). When each spool of
the lift arm and bucket of work equipment control valve (1) is at the Hold position, the oil
flows the drain circuit of work equipment control valve (1), is filtered on the return filter on
hydraulic tank (3), then is returned to hydraulic
tank (3).
q
Operating the work equipment lever operates
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 cylinder (2) to operate the lift arm or bucket.
q
The maximum pressure in the hydraulic circuit
is controlled with the relief valve in work equipment control valve (1). The bucket cylinder circuit 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 equipment 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 generation of negative pressure in the tank to prevent
cavitation in the pump.
10-600
SEN03928-00

WA320PZ-6
10-600

1. Work equipment control valve

2. Quick coupler solenoid valve
3. Bucket cylinder
4. Hydraulic tank
5. Attachment PPC valve
6. Work equipment PPC valve
7. Lock valve
8. Oil cooler
9. Check valve
10. 4-gear pump
Steering pump
Work equipment pump
11. Cut off valve
12. ECSS valve (if equipped)
13. Accumulator (for ECSS) (if equipped)
14. Lift cylinder
15. Coupler plunger
16. Accumulator (for PPC circuit)
SEN03928-00
Outline
q
The hydraulic system is consisted of the HST,
steering, work equipment, brake, cooling fan
and transfer lubrication circuit. The work equipment circuit controls move of the lift arm,
bucket and attachment.
q
The oil in hydraulic tank (4) is supplied to work
equipment control valve (1) by work equipment
pump of 4-gear pump (10). When each spool
of the lift arm, bucket and attachment of work
equipment control valve (1) is at the Hold position, the oil flows the drain circuit of work
equipment control valve (1), is filtered on the
return filter on hydraulic tank (4), then is
returned to hydraulic tank (4).
q
Operating the work equipment control lever
operates the lift arm spool or bucket spool of
work equipment PPC valve (6). If operating
the auxiliary control lever operates the spool of
attachment PPC valve (5).
The oil from work equipment PPC valve (6) or
attachment PPC valve (5) 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 equipment control valve (1). The bucket cylinder circuit 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 equipment 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 generation of negative pressure in the tank to prevent
cavitation in the pump.
10-600
SEN03928-00
Work equipment control lever linkage

WA320-6
Multi-function mono-lever type
1. Work equipment control lever

2. Directional selector switch
3. Wrist rest
4. Lock valve
5. Work equipment lock lever
7. Wrist rest height adjustment lock lever
10-600

SEN03928-00
WA320-6
2-lever type
(If equipped)
1. Lift arm control lever

2. Bucket control lever
3. Wrist rest
4. Lock valve
10-600
SEN03928-00

WA320PZ-6
Multi-function mono-lever type
1. Work equipment control lever

2. Auxiliary control lever
4. Wrist rest
5. Lock valve
10-600

SEN03928-00
WA320PZ-6
2-lever type
(If equipped)
1. Lift arm control lever

2. Bucket control lever
3. Auxiliary control lever
4. Wrist rest
5. Lock valve
10-600

Hydraulic tank
SEN03928-00
Hydraulic tank
1. Oil filler cap and breather

2. Return filter
3. Hydraulic tank
4. Drain plug
5. Sight gauge
6. Return filter bypass valve
7. Check valve
10-600
10
Specifications
Capacity of hydraulic tank (l)
124
Quantity of oil in hydraulic tank (l)
89
Set pressure of bypass valve

(MPa {kg/cm2})
Cracking pressure of check valve
(MPa {kg/cm2})
0.2
{2.04}
0.2 0.03
{1.96 0.29}

Hydraulic tank
Breather
SEN03928-00
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 differential pressure between the tank pressure and
the atmospheric pressure to prevent generation 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
While the hydraulic circuit is in operation, the
oil level in the tank rises as the hydraulic cylinders operate, and the temperature rises. Consequently, 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})
10-600
11

4-gear pump
SEN03928-00
4-gear pump
(steering, work equipment, brake, cooling fan and transfer lubrication)

Type: SAR(3)90 + (2)32 + SB(1)18 + 12
1. Steering pump
2. Work equipment pump
4. Transfer lubrication pump
10-600
12
Outline
q
The 4-gear pump is installed on the HST
pump. The axial rotation drives this gear to
supply pressurized oil to the steering, work
equipment, brake, cooling fan and transfer.

4-gear pump
SEN03928-00
Unit: mm
No.
Check item
Criteria
Type
Remedy
Standard clearance
Clearance limit
0.10 0.15
0.19
SAR(3)90
Side clearance
SAR(2)32
SBR(1)18
SBR(1)12
Clearance between inside diameter

of plain bearing and outside
diameter of gear shaft
SAR(3)90
0.083 0.144
SAR(2)32
0.071 0.121
SBR(1)18
SBR(1)12
Pin driven depth
Type
Standard size
SAR(3)90
13
SAR(2)32
12
SBR(1)18
10
SBR(1)12
Torque of spline rotating shaft
Delivery
Oil temperature: 45 55C
Allowance
0
0.5
Repair limit
+0.5
0
Speed
(rpm)
Discharge
pressure
(MPa {kg/cm2})
SAR(3)90
SAR(2)32
SBR(1)18
SBR(1)12
Replace
13.8 28.5 Nm {1.4 2.9 kgm}

Type
Oil: SAE10WCD
0.20
0.068 0.115
2,500
20.6 {210}
2.9 {30}
Standard
delivery
(l/min)
Allowable
delivery
(l/min)
208
192
72
65
40
35
27
24
10-600
13
SEN03928-00

WA320-6
2-spool type
10-600
14

SEN03928-00
A1: To bucket cylinder head

A2: To lift arm cylinder head
B1: To bucket cylinder bottom
B2: To lift arm cylinder bottom
P1A: From PPC valve P1 port
P1B: From PPC valve P3 port
T: Drain port (To tank)
10-600
15
SEN03928-00
10-600
16


SEN03928-00
1. Bucket spool
2. Lift arm spool
3. Suction valve
5. Check valve
6. Main relief valve
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Spool return spring (for bucket)
Repair limit
Free length x
Outside
diameter
Installed
length
Installed load
Free length
Installed load
54.8 x 34
53.5
125 N
{12.7 kg}
100 N
{10.2 kg}
Spool return spring

(for bucket and lift arm)
54.8 x 33.7
52.5
207.9 N
{21.2 kg}
167 N
{17 kg}
Spool return spring

30.7 x 32.5
26.5
255 N
{26 kg}
204 N
{20.8 kg}
return spring
10 Spool
(for lift arm)
51.9 x 16.9
40
182.4 N
{18.6 kg}
146 N
{14.9 kg}
return spring
11 Spool
(for lift arm)
87.6 x 34.7
83.5
229.5 N
{23.4 kg}
183 N
{18.7 kg}
12 Check valve spring
32.6 x 10.9
24.5
44.1 N
{4.5 kg}
35.3 N
{3.6 kg}
13 Suction valve spring
64.9 x 12.5
56
6.4 N
{0.65 kg}
5.1 N
{0.52 kg}
If damaged or
deformed, replace
spring
10-600
17
SEN03928-00

WA320-6
3-spool type
10-600
18

SEN03928-00
A1: To attachment cylinder

B1: To attachment cylinder
P1A: From attachment PPC valve
P1B: From attachment PPC valve
T: Drain port (to tank)
10-600
19
SEN03928-00
10-600
20


SEN03928-00
1. Attachment spool
2. Bucket spool
3. Lift arm spool
4. Suction valve
5. Safety-suction valve
6. Check valve
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
Free length x
Outside
diameter
Installed
length
Installed load
Free length
Installed load
54.8 x 34
53.5
125 N
{12.7 kg}
100 N
{10.2 kg}
Spool return spring

54.8 x 33.7
52.5
207.9 N
{21.2 kg}
167 N
{17 kg}
return spring
10 Spool
30.7 x 32.5
26.5
255 N
{26 kg}
204 N
{20.8 kg}
return spring
11 Spool
(for lift arm)
51.9 x 16.9
40
182.4 N
{18.6 kg}
146 N
{14.9 kg}
return spring
12 Spool
(for lift arm)
87.6 x 34.7
83.5
229.5 N
{23.4 kg}
183 N
{18.7 kg}
32.6 x 10.9
24.5
44.1 N
{4.5 kg}
35.3 N
{3.6 kg}
64.9 x 12.5
56
6.4 N
{0.65 kg}
5.1 N
{0.52 kg}
Spool return spring

(for bucket and attachment)
If damaged or
deformed, replace
spring
10-600
21
SEN03928-00

WA320PZ-6
2-spool type
10-600
22

SEN03928-00

T: Drain port (To tank)
10-600
23
SEN03928-00
10-600
24


SEN03928-00
1. Bucket spool
2. Lift arm spool
3. Suction valve
5. Check valve
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Spool return spring (for bucket)
Repair limit
Free length x
Outside
diameter
Installed
length
Installed load
Free length
Installed load
54.8 x 34
53.5
125 N
{12.7 kg}
100 N
{10.2 kg}
Spool return spring

54.8 x 33.7
52.5
207.9 N
{21.2 kg}
167 N
{17 kg}
Spool return spring

30.7 x 32.5
26.5
255 N
{26 kg}
204 N
{20.8 kg}
return spring
10 Spool
(for lift arm)
51.9 x 16.9
40
182.4 N
{18.6 kg}
146 N
{14.9 kg}
return spring
11 Spool
(for lift arm)
87.6 x 34.7
83.5
229.5 N
{23.4 kg}
183 N
{18.7 kg}
32.6 x 10.9
24.5
44.1 N
{4.5 kg}
35.3 N
{3.6 kg}
27.7 x 10.4
25
380 N
{38.8 kg}
304 N
{31 kg}
If damaged or
deformed, replace
spring
10-600
25
SEN03928-00

WA320PZ-6
3-spool type
10-600
26

SEN03928-00
A1: To attachment cylinder

B1: To attachment cylinder
P1A: From attachment PPC valve
P1B: From attachment PPC valve
T: Drain port (to tank)
10-600
27
SEN03928-00
10-600
28


SEN03928-00
1. Attachment spool
2. Bucket spool
3. Lift arm spool
4. Suction valve
5. Safety-suction valve
6. Check valve
Unit: mm
No.
Item
Criteria
Remedy
Standard size
Repair limit
Free length x
Outside
diameter
Installed
length
Installed load
Free length
Installed load
54.8 x 34
53.5
125 N
{12.7 kg}
100 N
{10.2 kg}
Spool return spring

54.8 x 33.7
52.5
207.9 N
{21.2 kg}
167 N
{17 kg}
return spring
10 Spool
30.7 x 32.5
26.5
255 N
{26 kg}
204 N
{20.8 kg}
return spring
11 Spool
(for lift arm)
51.9 x 16.9
40
182.4 N
{18.6 kg}
146 N
{14.9 kg}
return spring
12 Spool
(for lift arm)
87.6 x 34.7
83.5
229.5 N
{23.4 kg}
183 N
{18.7 kg}
32.6 x 10.9
24.5
44.1 N
{4.5 kg}
35.3 N
{3.6 kg}
27.7 x 10.4
25
376 N
{38.3 kg}
300 N
{30.6 kg}
Spool return spring

(for bucket and attachment)
If damaged or
deformed, replace
spring
10-600
29

SEN03928-00
Relief valve
q
q
q
If the oil pressure in ports (A) and (B) reaches

the set pressure of pilot poppet spring (4), pilot
poppet (3) opens.
The oil in port (A) flows through orifice (E) to
ports (B), (D), and (C).
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
equipment control valve. When the oil pressure
increases beyond the specified level, it drains
the oil to the hydraulic tank. Above process
protects the work equipment circuit by restricting the maximum pressure.
Operation
q
Port (A) is connected to the pump circuit and
port (C) is connected to the drain circuit. Oil
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
The differential pressure between ports (A)

and (B) pushes main valve (1) open, then the
oil in port (A) flows through port (C) to the drain
circuit to let the abnormal pressure escape.
The set pressure can be changed by increasing or decreasing the tension of pilot poppet
spring (4).
To change the set pressure, loosen the locknut. Then, tighten or loosen adjustment screw
(5) to heighten or lower the set pressure.

SEN03928-00
Safety-suction valve
1. Suction valve
2. Main valve
3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body
Function
q
The safety-suction valve is installed to the
bucket cylinder circuit in the work equipment
control valve. When an impact is applied to the
bucket cylinder and abnormal pressure is generated while the bucket control lever is in neutral, 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.
If abnormal pressure is generated in port (A),

suction valve (1) does not operate since (d2) >
(d1). At this time, however, main valve (2)
receives oil pressure for the differential area
between (d3) and (d4) since (d3) of port (A) >
(d4) of port (C).
If the abnormal pressure reaches the set pressure of main valve spring (3), main valve (2)
operates and the oil in port (A) flows to port
(B).
Operation
1. Operation as safety valve

q
q
Port (A) and port (B) are connected to the cylinder circuit and drain circuit, respectively.
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).
Pilot piston (4) is fixed to the safety valve and
the order of the diameters (areas) of the sections is (d2) > (d1) > (d3) > (d4).
10-600
31

SEN03928-00
2. Operation as suction valve
q
When negative pressure is generated in port

(A), the pressure in port (D) which is connected
to port (A) becomes negative.
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).
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).
When the pressure in port (A) lowers and
becomes almost negative, it is lower than oil
pressure (e).
When oil pressure (e) > oil pressure (a) + force
of valve spring (5), suction valve (1) opens and
the oil flows through port (B) to port (A), thus
the pressure in port (A) does not become negative.
Suction valve
1. Main poppet
2. Sleeve
3. Spring
Function
q
This valve prevents to generate negative pressure on the circuit.
Operation
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 pressurized oil flows to cylinder port (A) from tank port
(B).
10-600
32

SEN03928-00
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
maximum pressure is limited by relief valve (1).
q
The bypass circuit of bucket spool (2) is
opened to hold the lift arm. As a result, the oil
in port (A) flows around the spool into port (B).
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.
The oil from the PPC pump flows in port (L) of

the PPC valve. Since the lift arm and bucket
control levers are in the hold positions, however, the oil returns through the PPC relief
valve to the hydraulic tank.
10-600
33

SEN03928-00
2. When lift arm spool is at raise position
Operation
q
If the lift arm control lever is pulled, the oil flows
from port (L) of the PPC valve through port (N)
to port (S) of the work equipment control valve.
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 cylinder bottom.
10-600
34
The oil in the cylinder head flows through port

(E) into drain port (F) and then returns to the
tank. Accordingly, the lift arm is raised.

SEN03928-00
3. When lift arm spool is at lower position
Operation
q
If the lift arm control lever is pushed, the oil
flows from port (L) of the PPC valve through
port (M) to port (T) of work equipment control
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.
q
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.
The oil in the cylinder bottom flows through

port (D) into drain port (F) and then returns to
the tank. Accordingly, the lift arm is lowered.
10-600
35

SEN03928-00
4. When lift arm spool is at float position
Operation
q
If the lift arm control lever is pushed to the float
position, lift arm spool (3) moves over the
lower position to the float position.
q
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 connected to the drain circuit.
10-600
36
While the bucket is in contact with the ground,

it can move up and down according to the
unevenness of the ground.

SEN03928-00
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.
10-600
37
SEN03928-00

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

SEN03928-00
10-600
39
SEN03928-00
Cut-off valve
a

Cut-off valve
Do not disassemble.
If it is disassembled, its set pressure must be adjusted.
10-600
40

Cut-off valve
SEN03928-00
C1: To work equipment control valve

C2: From work equipment control valve
DA: DA port pressure
T1: To tank
T2: To tank
P: From work equipment pump
1. Unload valve
2. Check valve
3. Cut-off relief valve

4. Screen
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Unload valve spring
Check valve spring
Repair limit
Free length x
Outside
diameter
Installed
length
Installed load
Free length
Installed load
36.95 x 12.6
30
35.3 N
{3.6 kg}
28.4 N
{2.9 kg}
33 x 13.8
20
1.7 N
{0.17 kg}
1.4 N
{0.14 kg}
If damaged or
deformed, replace
spring
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.
10-600
41
SEN03928-00
1. When work equipment pump pressure is
lower than cut-off pressure
q
Similarly to the state where the work equipment is held, the oil of the work equipment
pump pushes up check valve (1) and merges
with the oil from the steering pump and then
flows into the work equipment control valve.
10-600
42

Cut-off valve
2. When work equipment pump pressure is

higher than cut-off pressure
q
If the work equipment pump pressure reaches
the cut-off pressure, cut-off valve (2) is opened
by the oil pressure in chamber (a) and then the
oil in chamber (b) of unload valve (3) is drained
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.

PPC valve
SEN03928-00
PPC valve
a
PPC: Abbreviation for Proportional Pressure Control

Mono-lever type

P1: To bucket valve (tilt)
P2: To bucket valve (dump)
P3: To lift arm valve (raise)

P4: To lift arm valve (lower, float)
10-600
43

PPC valve
SEN03928-00
1. Spool
2. Metering spring
3. Centering spring
4. Rod
5. Disc
6. Nut (for connecting lever)
10-600
44
7. Joint
8. Plate
9. Piston
10. Retainer
11. Body
12. Filter

PPC valve
SEN03928-00
Operation
When in neutral
1) Bucket PPC valve
q
Ports (PA) and (PB) of the control valve
(bucket valve) and ports (P1) and (P2) of the
PPC valve are connected through fine control
hole (f) of spool (1) to drain chamber (D).
2) Lift arm PPC valve

q
Ports (PA) and (PB) of the control valve (lift
arm valve) and ports (P3) and (P4) of the PPC
valve are connected through fine control hole
(f) of spool (1) to drain chamber (D).
10-600
45
SEN03928-00

PPC valve
When in fine control

(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), it is almost simultaneously interconnected 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
When the pressure at port (P1) becomes
higher, spool (1) is pushed back and fine control hole (f) is shut off from pump pressure
chamber (PP). At almost the same time, it is
connected to drain chamber (D) to release the
pressure at port (P1).
q
As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced
with the pressure at port (P1).
q
The positional relationship between spool (1)
and body (11) (where fine control hole (f) is
between drain chamber (D) and pump pressure chamber (PP)) does not change until
retainer (10) comes in contact with spool (1).
q
Metering spring (2) contracts in proportion to
the stroke of the control lever.
q
Pressure at port (P1) also rises in proportion to
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

PPC valve
When in fine control mode

(when control lever is returned)
q
When disc (5) starts to be returned, spool (1) is
pushed up by the force of centering spring (3)
and the pressure at port (P1).
q
Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released.
q
If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering
spring (2).
q
Fine control hole (f) is shut off from drain
chamber (D), and it is almost simultaneously
interconnected to pump pressure chamber
(PP).
q
Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q
When the control valve spool returns, the pressurized 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).
SEN03928-00
When lever is operated to stroke end
q
Disc (5) and rod (4) push down piston (9) and
retainer (10) pushes down spool (1).
q
chamber (D), and is interconnected to pump
pressure chamber (PP).
q
The pilot pressure oil from the HST charge
port (P1) into chamber (PB) to push the control
valve spool.
q
The oil returning from chamber (PA) flows
through port (P2) and fine control hole (f') into
drain chamber (D).
10-600
47
SEN03928-00

PPC valve
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.
When "float" state of lift arm is reset

When returning disc (5) from the "float" position, 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 (deenergizing the solenoid).
q
The lift arm raise and bucket tilt operations are

carried out similarly to the above.
10-600
48

PPC valve
SEN03928-00
2-lever type

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

PPC valve
SEN03928-00
1. Spool
2. Metering spring
3. Centering spring
4. Rod
5. Lever
6. Ring
10-600
50
7. Plate
8. Piston
9. Retainer
10. Body
11. Filter

PPC valve
SEN03928-00
Operation
When in neutral
1) Bucket PPC valve
q
Ports (PA) and (PB) of the control valve
(bucket valve) and ports (P1) and (P4) of the
PPC valve are connected through fine control
hole (f) of spool (1) to drain chamber (D).
2) Lift arm PPC valve

q
Ports (PA) and (PB) of the control valve (lift
arm valve) and ports (P2) and (P3) of the PPC
valve are connected through fine control hole
(f) of spool (1) to drain chamber (D).
10-600
51
SEN03928-00

PPC valve
When in fine control

(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), it is almost simultaneously interconnected to pump pressure chamber (PP).
q
The pilot pressurized oil from the HST charge
port (P1) to port (PB).
q
If the pressure in port (P1) rises, spool (1) is
pushed back and fine control hole (f) is disconnected from pump pressure chamber (PP) and
connected to drain chamber (D) almost simultaneously to release the pressure in port (P1).
q
As a result, spool (1) moves up and down until
the force of metering spring (2) is balanced
with the pressure at port (P1).
q
The positional relationship between spool (1)
and body (10) [where fine control hole (f) is
between drain chamber (D) and pump pressure chamber (PP)] does not change until
retainer (9) comes in contact with spool (1).
q
Metering spring (2) contracts in proportion to
q
Pressure at port (P1) also rises in proportion to
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

PPC valve
When in fine control mode

(when control lever is returned)
q
If lever (5) begins to return, the force of centering spring (3) and the pressure in port (P1)
push up spool (1).
q
Because of this, fine control hole (f) is connected to drain chamber (D), and the pressurized oil at port (P1) is released.
q
If the pressure of port (P1) is lowered excessively, spool (1) is pushed down by metering
spring (2).
q
chamber (D), and it is almost simultaneously
interconnected to pump pressure chamber
(PP).
q
Pump pressure is supplied until the pressure at
port (P1) recovers to the level equivalent to the
lever position.
q
When the control valve spool returns, the pressurized 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).
SEN03928-00
When lever is operated to stroke end
q
Lever (5) and rod (4) push down piston (8) and
retainer (9) pushes down spool (1).
q
chamber (D), and is interconnected to pump
pressure chamber (PP).
q
The pilot pressure oil from the HST charge
port (P1) into chamber (PB) to push the control
valve spool.
q
The oil returning from chamber (PA) flows
through port (P4) and fine control hole (f') into
drain chamber (D).
10-600
53
SEN03928-00

PPC valve
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.
When "float" state of lift arm is reset

When returning lever (5) from the "float" position, 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 (deenergizing the solenoid).
q
The lift arm raise and bucket tilt operations are

carried out similarly to the above.
10-600
54

PPC valve
SEN03928-00
10-600
55

PPC valve
SEN03928-00
Attachment PPC valve
For the details of operation, see the paragraph of "Work equipment PPC valve".
10-600
56

PPC valve
SEN03928-00

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
No.
Item
Criteria
Remedy
Standard size
Centering spring
Metering spring
Repair limit
Free length x
Outside
diameter
Installed
length
Installed load
Free length
Installed load
41.1 x 15.5
29
36.3 N
{3.7 kg}
29.0 N
{2.96 kg}
22.73 x 8.1
22
16.7 N
{1.7 kg}
13.3 N
{1.36 kg}
If damaged or
deformed, replace
spring
10-600
57

Lock valve
SEN03928-00
Lock valve
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 equipment operation.
10-600
58

Accumulator (for PPC circuit)
SEN03928-00
Accumulator (for PPC circuit)
1. Gas plug
2. Poppet
3. Holder
4. Bladder
5. Film
6. Shell
7. Oil port
Outline
q
This accumulator is installed between the
charge valve and work equipment PPC valve.
Even if the engine stops with the work equipment 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
Gas used
Nitrogen gas
Amount of gas (cc)
500
Charged pressure
(MPa {kg/cm2})
1.18(+0.2/0) {12(+2/0)}
(at 80C)
Max. pressure used

(MPa {kg/cm2})
3.92 {40}
10-600
59
SEN03928-00
Quick coupler solenoid valve

Quick coupler solenoid valve
WA320PZ-6
P: From work equipment control valve port B2

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

ECSS valve
SEN03928-00
ECSS valve
(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)
10-600
61
SEN03928-00

ECSS valve
1. Main spool
2. Solenoid valve
3. Flow control valve
4. Shuttle valve
5. Charge valve
10-600
62

Accumulator (for ECSS)
SEN03928-00
Accumulator (for ECSS)
(If equipped)
1. Valve
2. Top cover
3. Cylinder
4. Free piston
Function
q
This 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 compressibility.
Specifications
Gas used
Nitrogen gas
Amount of gas (cc)
3,000
Charged pressure
(MPa {kg/cm2})
2.0 0.1 {20 1}

(at 20C)
Max. pressure used

(MPa {kg/cm2})
20.6 {210}
10-600
63
SEN03928-00

2008 KOMATSU
All Rights Reserved
10-600
64
SEN03929-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up

10
700 Work equipment

Work equipment linkage ................................................................................................................................. 2
Bucket ............................................................................................................................................................. 6
Bucket positioner and boom kick-out ............................................................................................................ 10
Work equipment cylinder .............................................................................................................................. 22
10-700
SEN03929-01
Work equipment linkage
700 Work equipment

WA320-6
10-700
700 Work equipment

SEN03929-01
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
Unit: mm
No.
7
Check item
Clearance between bushing and pin
at each end of bucket link
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
75
0.030
0.076
+0.174
+0.100
0.130
0.250
1.0
Standard
size

connecting lift arm and bucket
75
0.030
0.076
+0.174
+0.100
0.130
0.250
1.0

connecting lift arm and frame
85
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
95
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
95
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
110
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
85
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
85
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
10 connecting bucket cylinder bottom

and frame
11 connecting bucket cylinder rod and

bell crank
between bushing and pin
12 Clearance
connecting bell crank and lift arm
13 connecting lift cylinder rod and lift

arm
14 connecting lift cylinder bottom and

frame
Width of boss
Width of hinge
Tolerance
Standard
size
Tolerance
Standard
clearance
90
0
0.5
93
1.5
1.5 5.0
part of lift arm and

16 Connecting
frame
105
109
1.5
2.5 5.5

17 Connecting
bucket
105
108
+1.5
0
3.0 4.5
part of bucket link and

18 Connecting
bucket
104
+2.8
0.5
109
+1.5
0
2.2 7.0
part of lift cylinder and

19 Connecting
frame
85
0
0.5
89
1.5
2.5 6.0
part of bell crank and

20 Connecting
bucket link
104
+2.8
0.5
109
1.5
0.7 7.0
part of bell crank and lift

21 Connecting
arm
194
0.5
197
0.5
2.0 4.0
part of bucket cylinder

22 Connecting
and bell crank
90
0
0.5
93
1.5
1.5 5.0
part of lift arm and lift

23 Connecting
cylinder
85
88
1.5
1.5 4.5

15 Connecting
and frame
Standard
size
Replace
(Replace pin when
it has scuff marks,
too.)
Adjust shim so that

clearance will be
below 1.5 mm on
each side
Replace
Adjust shim so that

clearance will be
below 1.5 mm on
each side
10-700
SEN03929-01
700 Work equipment

WA320PZ-6
10-700
700 Work equipment

SEN03929-01
1. Bucket
2. Bell crank
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
7. Quick coupler
Unit: mm
No.
Check item
Criteria
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
85
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0

connecting lift arm and quick
coupler
75
0.030
0.076
+0.174
+0.100
0.130
0.250
1.0

10 Clearance
connecting lift arm and frame
85
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
110
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
110
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
110
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
85
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
85
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0

at each end of bucket link
Standard
size
11 connecting bucket cylinder bottom

and frame
12 connecting bucket cylinder rod and

bell crank
13 Clearance
connecting bell crank and lift arm
14 connecting lift cylinder rod and lift

arm
15 connecting lift cylinder bottom and

frame
Width of boss
16 Connecting
and frame

17 Connecting
frame
Width of hinge
Tolerance
Standard
size
Tolerance
Standard
clearance
110
0
0.5
114
1.5
2.5 6.0
105
109
1.5
2.5 5.5
3.0 4.5
Standard
size
Replace
(Replace pin when
it has scuff marks,
too.)
Adjust shim so that

clearance will be
below 1.5 mm on
each side
part of lift arm and quick

18 Connecting
coupler
105
108
+1.5
0
part of bucket link and

19 Connecting
quick coupler
108
1.0
112
+1.5
0
3.0 6.5
part of lift cylinder and

20 Connecting
frame
85
0
0.5
89
1.5
2.5 6.0
part of bell crank and

21 Connecting
bucket link
108
1.0
112
1.5
1.5 6.5
part of bell crank and lift

22 Connecting
arm
194
196
+1.5
0.5
1.5 3.5
Replace

23 Connecting
and bell crank
110
0
0.5
112
1.5
0.5 4.0
part of lift arm and lift

24 Connecting
cylinder
84
88
1.5
2.5 5.5
Adjust shim so that

clearance will be
below 1.5 mm on
each side
10-700
700 Work equipment

Bucket
SEN03929-01
Bucket
WA320-6
1. Bucket
2. Wear plate
3. Bolt-on cutting edge
10-700
4. Bucket teeth (if equipped)

5. Adapter
700 Work equipment

Bucket
SEN03929-01
Unit: mm
No.
6
Check item
Criteria
Repair limit
31.8
19
90
Tooth
46
21
Tip tooth
48
36
Max. 0.5
Wear of cutting edge (thickness)
Wear of cutting edge (length)
Wear of bucket teeth
Remedy
Standard size
Reverse or replace
Replace
Clearance in adapter mounting

parts
Adjust or replace
10-700
700 Work equipment

Bucket
SEN03929-01
WA320PZ-6
1. Bucket
2. Bolt-on cutting edge
10-700
3. Bucket teeth (if equipped)

4. Adapter (if equipped)
700 Work equipment

Bucket
SEN03929-01
Unit: mm
No.
5
Check item
Criteria
Repair limit
31.8
19
90
Tooth
46
21
Tip tooth
48
36
Max. 0.5
Wear of cutting edge (thickness)
Wear of cutting edge (length)
Wear of bucket teeth
Remedy
Standard size
Reverse or replace
Replace
Clearance in adapter mounting

parts
Adjust or replace
10-700
700 Work equipment

Bucket positioner and boom kick-out
SEN03929-01
WA320-6
1. Bucket positioner proximity switch

2. Boom kick-out proximity switch
3. Bar
4. Bucket cylinder
5. Lift arm
6. Plate
Unit: mm
No.
Check item
Criteria
Clearance on bucket positioner

proximity switch
35
Clearance on boom kick-out

proximity switch
35
10-700
10
Remedy
Adjust
700 Work equipment

SEN03929-01
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 cylinder (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 sensing 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, proximity switch (2) detects that it is away from the
sensing face, and returns the work equipment
(lift arm) control lever to "hold" position.
10-700
11
700 Work equipment

SEN03929-01
Operation of proximity switch
When bucket is tilted
While the bucket is dumped more than the

position being set from the bucket positioner,
bar (2) moves on to the sensing face of proximity switch (1), turning on the proximity switch
(1) lamp.
At this point, bucket positioner relay (4) is "ON"
and current flows to detent solenoid (6) of work
equipment PPC valve (5) to energize the coil.
10-700
12
Shifting work equipment (bucket) control lever

(7) toward the tilt position moves spool (8) to
the position of the arrow. And spool is held
there by the energized coil of detent solenoid
(6).
As a result, work equipment (bucket) control
lever (7) is held at "tilt" position and the bucket
tilts.
700 Work equipment

SEN03929-01
a
The power supply for detent solenoid (6) operation 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 alternator 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
Bucket positioner relay
Work equipment PPC valve detent
solenoid circuit
solenoid
Turned ON
ON
Power ON
Energized
When object of sensing is apart from sensing

face of proximity switch
solenoid circuit
solenoid
Turned OFF
OFF
Power OFF
De-energized
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 sensing face of proximity switch (1), the lamp of
proximity switch (1) goes off and bucket positioner 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.
10-700
13
700 Work equipment

SEN03929-01
When lift arm is raised
While lift arm (3) is dumped beyond the position set from the boom kick-out, plate (2)
moves on to the sensing face of proximity
switch (1), turning on the proximity switch (1)
lamp.
At this point, boom kick-out relay (4) is "ON"
10-700
14
Shifting work equipment (lift arm) control lever

(7) toward the raise position moves spool (8) to
(6).
As a result, work equipment (lift arm) control
lever (7) is held at "raise" position and lift arm
(3) rises.
700 Work equipment

SEN03929-01
a
relay (11).
Detent solenoid (6) circuit is cut off since L signal 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 positioned in sensing face of proximity switch (1).

Boom kick-out relay
solenoid circuit
solenoid
Turned ON
ON
Power ON
Energized

proximity switch
Boom kick-out relay
solenoid circuit
solenoid
Turned OFF
OFF
Power OFF
De-energized
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.
10-700
15
700 Work equipment

SEN03929-01
WA320PZ-6
1. Fork positioner proximity switch

2. Bucket positioner proximity switch
3. Boom kick-out proximity switch
4. Bar
5. Bucket cylinder
6. Lift arm
7. Plate
Unit: mm
No.
Check item
Criteria
Clearance on bucket positioner

proximity switch
35
Clearance on boom kick-out

proximity switch
35
10-700
16
Remedy
Adjust
700 Work equipment

SEN03929-01
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" position 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 cylinder (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" position 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 equipment (bucket or fork) control lever to "hold"
position.
q
While the attachment selector switch of the
right-hand console is in the "BUCKET" position, 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, proximity switch (3) detects that it is away from the
sensing face, and returns the work equipment
(lift arm) control lever to "hold" position.
10-700
17
700 Work equipment

SEN03929-01
Operation of proximity switch
When bucket is tilted

a The case when the attachment selector switch is in the "BUCKET" position is shown below.
While the bucket is dumped more than the

position being set from the bucket positioner,
bar (2) moves on to the sensing face of proximity switch (1), turning on the proximity switch
(1) lamp.
At this point, bucket positioner relay (4) is "ON"
10-700
18
Shifting work equipment (bucket) control lever

(7) toward the tilt position moves spool (8) to
(6).
As a result, work equipment (bucket) control
lever (7) is held at "tilt" position and the bucket
tilts.
700 Work equipment

SEN03929-01
a
relay (11).
Detent solenoid (6) circuit is turned off since L
signal from alternator (10) is not sent to alternator 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
solenoid circuit
solenoid
Turned ON
ON
Power ON
Energized

solenoid circuit
solenoid
Turned OFF
OFF
Power OFF
De-energized
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 sensing face of proximity switch (1), the lamp of
proximity switch (1) goes off and bucket positioner relay (4) is set to "OFF" state.
Held bucket spool (8) receives the reaction
(bucket) control lever (7) to "hold" position.
10-700
19
700 Work equipment

SEN03929-01
When lift arm is raised
While lift arm (3) is dumped beyond the position set from the boom kick-out, plate (2)
moves on to the sensing face of proximity
switch (1), turning on the proximity switch (1)
lamp.
At this point, boom kick-out relay (4) is "ON"
10-700
20
Shifting work equipment (lift arm) control lever

(7) toward the raise position moves spool (8) to
(6).
As a result, work equipment (lift arm) control
lever (7) is held at "raise" position and lift arm
(3) rises.
700 Work equipment

SEN03929-01
a
relay (11).
Detent solenoid (6) circuit is cut off since L signal 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 positioned in sensing face of proximity switch (1).

proximity switch
Boom kick-out relay
solenoid circuit
solenoid
Turned ON
ON
Power ON
Energized

Boom kick-out relay
solenoid circuit
solenoid
Turned OFF
OFF
Power OFF
De-energized
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.
10-700
21
700 Work equipment

Work equipment cylinder
SEN03929-01
WA320-6
Lift cylinder
Bucket cylinder
Unit: mm
No.
Check item
Clearance between
piston rod and bushing
10-700
22
Criteria
Cylinder
name
Standard
size
Lift
Bucket
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
75
0.030
0.076
+0.279
+0.065
0.095
0.355
0.655
80
0.030
0.076
+0.258
+0.048
0.078
0.334
0.634
Replace bushing
700 Work equipment

SEN03929-01
WA320PZ-6
Lift cylinder
Bucket cylinder
Coupler plunger
Unit: mm
No.
Check item
Clearance between
piston rod and bushing
Criteria
Cylinder
name
Standard
size
Lift
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
75
0.030
0.076
+0.279
+0.065
0.095
0.355
0.655
Bucket
110
0.036
0.090
+0.261
+0.047
0.083
0.351
0.651
Coupler
plunger
20
0.020
0.072
-0.081
0.009
0.011
0.153
0.453
Replace bushing
10-700
23
SEN03929-01

2009 KOMATSU
All Rights Reserved
10-700
24
SEN03930-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up

10

Cab ................................................................................................................................................................. 3
Air conditioner ................................................................................................................................................. 4
10-800
SEN03930-00
10-800

Cab
SEN03930-00
Cab
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
8. KOMTRAX communication antenna
9. Door (right)
10. Rear wiper
10-800

Air conditioner
SEN03930-00
Air conditioner
Air conditioner piping diagram
10-800
1
1

Air conditioner
1. Hot water take-out piping

2. Compressor
3. Condenser
4. Receiver
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
SEN03930-00
Specifications
Refrigerant used
R134a
Refrigerant refilling level (g)
900
10-800

Air conditioner
SEN03930-00
Refrigerant circuit diagram
1. Engine
2. Compressor
3. Condenser
4. Receiver
5. Air conditioner unit
Table of tightening torque for refrigerant piping adapter
Unit: Nm {kgm}
No.
Check item
Criteria
Air conditioner unit refrigerant inlet side
12 15 {1.2 1.5}
(screw size: M16 x 1.5)
Air conditioner unit refrigerant outlet side
30 35 {3.1 3.6}
Receiver refrigerant pipe set bolt
8 12 {0.8 1.2}
10 Compressor refrigerant piping lock bolt
20 25 {2.0 2.6}
11 Condenser refrigerant inlet side
20 25 {2.0 2.6}
12 Condenser refrigerant outlet side
12 15 {1.2 1.5}
10-800
Remedy
Retighten

Air conditioner
SEN03930-00
Air conditioner unit
A: From receiver
B: To compressor
C: Hot water inlet
D: Hot water outlet
1. Evaporator
2. Heater core
3. Air mix damper (upper)
4. Air mix damper (lower)
5. Expansion valve
6. Blower controller
7. Blower motor relay
8. Compressor clutch relay
9. Air mix damper actuator
10. Evaporator temperature sensor
Outline
q
The vertical air conditioner unit on which evaporator (1) and heater core (2) is synchronized
with the blower and intake unit to generate cool
and hot air.
q
The temperature adjusting switch on the air
conditioner panel controls air mix dampers (3)
and (4) to adjust the spurting out temperature.
Cooler
The cooler circulates refrigerant through evaporator (1) to cause heat exchange (dehumidification and cooling).
q
Air taken in by the blower and intake unit is
cooled with evaporator (1) and then blown out
from the duct and grill.
q
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.
10-800

Air conditioner
SEN03930-00
Functions of major components
Evaporator
q
Evaporator fin is cooled by the low-pressure,
low-temperature refrigerant gas being sent
from the expansion valve. Air from the blower
motor is cooled and dehumidified when passing through the fin.
Heater core
q
Fin of the heater core is heated by the hot
water (cooling) being sent from the engine. Air
from the blower motor is heated as it passes
through the fin.
Expansion valve
This valve converts high-pressure, high-temperature liquid refrigerant from the receiver to
low-pressure, low-temperature misty refrigerant through the throttling function.
It controls flow rate of refrigerant by changing
level of throttling depending on the thermal
load in the operator's cab.
Blower controller
q
It controls the blower motor speed receiving
signal current from the air conditioner panel.
Blower motor relay
q
Signal current from the air conditioner panel
controls the relay coil. As the relay coil is energized and the switch is turned "ON", power is
supplied to the blower motor.
Air mix damper actuator

q
It starts the built-in motor receiving signal current from the air conditioner panel in order to
open or close the air mix damper through the
link mechanism.
q
The motor rotating direction is determined as
the air conditioner panel reads the position of
the potentiometer being built in the actuator.
This reading is done as the target temperature
is set from the temperature adjustment switch
on the air conditioner panel.
q
Rotation of the motor is stopped as the contact, which is to move interlocked with the
motor, moves away or signal current from the
air conditioner panel is turned "OFF".
Evaporator temperature sensor
q
In order to prevent freezing of the evaporator, it
senses the evaporator temperature and sends
necessary signals to the air conditioner panel.
The signal sent to the air conditioner panel is
used to control the compressor. As the result,
temperature of the air blown out of the grill is
adjusted depending on the volume of refrigerant circulated in the evaporator.
Dual pressure switch
If abnormally low or high pressure was generated in the refrigerant circulation circuit, this
switch releases the magnet clutch of the compressor 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

Air conditioner
SEN03930-00
Blower and intake unit
1. Blower motor assembly

2. Internal/external air changeover damper actuator
3. Internal/external air changeover damper
Functions of major components

Blower motor assembly
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 conditioner 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 contact, which is to move interlocked with the
motor, moves away or signal current from the
air conditioner panel is turned "OFF".
10-800
SEN03930-00

Air conditioner
Compressor
A: From air conditioner unit

B: To condenser
Function
q
Other than circulating the refrigerant, it compresses the refrigerant gas from the evaporator 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
10-800
10
Number of cylinders
Bore x Stroke (mm)
7 29.3 x 27.4
Piston capacity (cc/rev)
129.2
Allowable maximum speed

(rpm)
4,000
Refrigerant oil used
Sanden: SP-10
Refrigerant oil refilling volume

(cc)
135

Air conditioner
SEN03930-00
Condenser
A: From compressor
B: To receiver
Function
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 unavailable. As the result, pressure in the refrigerant
circulation circuit will be increased, applying
extra load to the engine or degrading the cooling effect. Thus, care must be used in its handling and daily inspection.
Specifications
Fin pitch (mm)
1.5
Total heat dissipation area (m2)
6.55
Max. pressure used

(MPa {kg/cm2})
3.6 {36}
10-800
11

Air conditioner
SEN03930-00
Receiver
A: From condenser
B: To air conditioner unit
1. Sight glass
Function
q
It is used to store liquefied high-pressure, hightemperature misty refrigerant from the condenser. It is capable of completely liquefying
the refrigerant even when bubbles are contained in the refrigerant due to the condenser
condition in heat dissipation.
q
It eliminates foreign substances in the circulation 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
10-800
12
Effective cubic capacity (cm3)
578
Weight of desiccating agent (g)
300

Air conditioner
SEN03930-00
10-800
13

Air conditioner
SEN03930-00
Air conditioner panel
Display unit
No.
Display
category
1
Gauge
2
3
Pilot
4
Display items
Display range
Display method
Spurting out
temperature
Air blasting
volume
See above
drawing
See above
drawing
All segments below applicable level come

on (8-step display)
All segments below applicable level come
on (4-step display)
The display indicates which is currently
taking place - internal air circulation or
external air introduction - responding to the
operation of the internal/external air
changeover switch.
Circulation of
internal air and
introduction of
external air
When circulating
internal air and
introducing
external air
Air conditioner
When air
Turns "ON" air conditioner switch, this lamp
conditioner switch
lights up.
is "ON"
Display
Remarks
color
Black
Liquid
crystal
Switch block
No.
Switch name
Function
Operation
Circulation of
internal air
IO
Introduction of
external air
OFF io ON
Internal/external air
changeover switch
This switch is used to select either the circulation of internal air or

introduction of external air
(pilot display on the display unit is switched depending on the switch
setting)
Air conditioner switch
It turns on or off the cooling and the dehumidifying heating function.
Main power switch
Fan switch
Temperature adjusting
switch
10-800
14
It turns on or off main power supply of the air conditioner.

ON: Settings done during "OFF" are indicated on the display unit.
OFF: Turns off the display unit lamp and stops the fan.
It controls volume of air sent from the fan.
(adjusted in 4 steps [LO, M1, M2 and HI])
It controls the spurting out temperature
(8-step adjustment)
OFF io ON
LO io HI
Low temperature
IO
High temperature

Air conditioner
SEN03930-00
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]
Pin No.
Signal name
JAE IL-AG5-22P [CN-C47]

Input and
output
signals
Pin No.
Input and
output
signals
Signal name
GND
NC
Sensor ground
NC
Internal/external air changeover damper

actuator limiter
Input
Blower motor relay
External air temperature sensor
Input

actuator output 1
Output

actuator output 2
Output
Input
Evaporator temperature sensor
Input
Internal air temperature sensor
Input
Starting switch (ON)
Input
Mode selector actuator output 2
Output
Input
Mode selector actuator output 1
Output
Air mix damper actuator output 2
Output
Air mix damper actuator output 1
Output
10
Actuator potentiometer power supply

(5 V)
8
9
10
Night lamp signal

NC
NC
11
NC
12
NC
13
Day light sensor 2
Input
14
Day light sensor 1
Output
11
NC
12
NC
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
10-800
15
SEN03930-00

2008 KOMATSU
All Rights Reserved
10-800
16
SEN03931-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up

10

Machine monitor system ................................................................................................................................. 2
Machine monitor ............................................................................................................................................. 6
10-910

Machine monitor system
SEN03931-01

Outline
q
In the machine monitor system, each controller
on the network monitors controls the machine
condition with the sensors installed to various
parts of the machine, and then sends the result
as network information to the machine monitor,
which displays the information to notify the
operator of the machine condition.
q
The machine monitor displays the information

in the operator mode or service mode.
The operator mode is used to display the information to the operator normally. The major
functions used in the service mode are as follows.
1.
Items always displayed

q
Meters (speedometer or engine tachometer)
q
Gauges (engine coolant temperature
gauge, HST oil temperature gauge and
fuel gauge)
q
Pilot indicators
q
Service meter
4.
In addition to the above, the following display,

setting and adjustment functions are provided
using the character display and the machine
monitor mode selector switch, which is the
operation switch of the character display.
1) Switching of traction level
2) Switching of HST reverse travel gear shifting pattern
3) Display the odometer
4) Resetting the filter or oil replacement time
5) Input the telephone number
6) Selecting the language
7) Adjusting the illuminance of nighttime light
8) Travel speed/engine speed display selecting function
9) Function for setting display/no-display of
travel speed or engine speed to the character display
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 displayed, if the machine monitor mode
selector switch (>) is pressed and
released, the failure code (6 digits) is displayed.)
3.
At the replacement period of a filter or oil, the

character display displays that filter or oil.
(maintenance monitoring function)
10-910

1.
The service mode function is provided for the

ease of troubleshooting for the controllers on
the network (including the machine monitor
itself). The major functions used in this mode
are as follows.
Electrical system failure history display function
The electrical system failures of each controller
saved in the machine monitor are displayed.
The information of those failures is also
deleted with this function.
2.
Mechanical system failure history display function

The mechanical system failures of each controller saved in the machine monitor are displayed.
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 specifying 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 storing 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 dispersion 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.
SEN03931-01
10. Machine serial number input function
Enters the machine serial number to identify
the machine.
11. Model selection function
Enters the information of applicable model.
12. Initialize function
Sets the machine monitor to the state set when
the machine is delivered.
10-910
SEN03931-01

System circuit diagram

a
Items marked with "*1" in drawing may or may not installed.
10-910

SEN03931-01
10-910

Machine monitor
SEN03931-01
Machine monitor
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
HST oil temperature gauge

HST oil temperature caution lamp
Engine coolant temperature gauge
Engine coolant temperature caution lamp
Speedometer or engine tachometer
Turn signal pilot lamp (left)
Head lamp high beam pilot lamp
Turn signal pilot lamp (right)
Fuel level caution lamp
Fuel gauge
Central warning lamp
Brake oil pressure caution lamp
Engine oil pressure caution lamp
Water separator caution lamp
Engine oil level caution lamp
Radiator coolant level caution lamp
HST oil filter clogging caution lamp
Air cleaner clogging caution lamp
Parking brake pilot lamp
Brake oil temperature caution lamp
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
Quick coupler operation pilot lamp (*2)

Cooling fan reverse rotation pilot lamp
Maintenance caution lamp
Parking brake reminder caution lamp
Battery charge circuit caution lamp
Steering oil pressure caution lamp (*2)
Emergency steering pilot lamp (*2)
Meter display pilot lamp
Character display portion
Preheating pilot lamp
Directional selector switch actuation pilot lamp
(*2)
Economy operation display lamp
Shift hold pilot lamp (*1)
S mode operation pilot lamp
Traction control operation pilot lamp
Travel speed range selector switch position
pilot lamp
Directional lever position pilot lamp
*1: Not used by this model

*2: If equipped
10-910

Machine monitor
SEN03931-01
List of items displayed on monitor
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
Period: 1,600 msec.

ON: 800 msec.
OFF: 800 msec. (duty 50%)
w: Intermittent
sounds
Warning for dangerous

condition (error or caution
message is generated)
w: Flashing
Period: 1,600 msec.

ON: 800 msec.
OFF: 800 msec. (duty 50%)
A: Intermittent
sounds
Caution for erroneous

Period: 240 msec.
operation (when an irregular ON: 80 msec.
operation is done)
OFF: 160 msec.
A: Intermittent
Period: 240 msec.

ON: 80 msec.
OFF: 160 msec.
E: Canceling
sounds
Set cancellation such as

calibration (inoperative state) ON: 1,000 msec. (1 time)
e: Completion
sounds
Completion of setting such

ON: 100 msec.
as calibration (when normally OFF: 160 msec.
ended)
ON: 100 msec. (1 time)
1
2
HST oil
temperature
Engine coolant
temperature
LED
When lamp switch is other

than "OFF"
Other than below
Caution
lamp: LED
10
w Q Q B@CRNS w Q Q B@CRNS
When abnormality is
detected (out of input signal
range)
20
DGH1KX
9
10
Pointer:
Movement
Fuel level
Caution
lamp: LED
Display color
DGH1KX
Alarm: 105C or above
w Q Q B@BCNS w Q Q B@BCNS
When abnormality is
detected (high temperature)
CA144
CA144
When abnormality is
detected (low temperature)
CA145
CA145
When engine speed display

is selected
When travel speed display is

selected
Other than below
10
When abnormality is
detected (input voltage is 4
V or above and no incoming
IGN-C signal is detected)
10
DJF1KA
When a communication error is

detected, the system displays
"0".
Max: 10 z
Min: 85 z
When the sensor is

disconnected or hot shortcircuited: Max
When sensor was
disconnected or hot shortcircuited: Min
(selectable with the machine

monitor setting)
Min. 80 z
When the sensor is

disconnected or hot shortcircuited: Max
When sensor was
disconnected or hot shortcircuited: Min
White range: 50 102C

Red range: 102 135C
Caution
lamp: LED
Pointer:
Movement
Turned ON with errors (E03

and E02) of each controller,
simultaneously displaying the
message on the character
display.
White range: 30 105C

Red range: 105 135C
Pointer:
Movement
Travel speed
Gauges and
meters
Display of
message
Red

Pointer:
Movement
Engine speed
5
Alarm buzzer
Reset
For other than above, see

"Operating condition, central
warning lamp" of other
items.
LED

3
4
E E E
E E E
Other than below
Gauges and
meters
When error occurs
Remarks
White
Back light
Operating condition
Red
Central
warning
Device
Red
Back light
11
Item
Engine is running
Red
Central
warning lamp
No.
Operating condition
Engine stopped
Alarm buzzer
Category
Detection
Detecting
time
(sec)
Individual display
Central warning
lamp
Display of
message
E: Separately
set conditions
Individual display
Central warning
lamp
Q: ON
DJF1KA
When the sensor is grounded:

Full
When sensor was
disconnected or hot shortcircuited: Empty
10-910

Machine monitor
SEN03931-01
Engine speed
When engine speed display

is selected
When travel speed display is

selected
When F is selected (neutral

safety is displayed as engine
is stopped)
A Q Q
LED
When N is selected
LED
When R is selected (neutral

safety is displayed as engine
is stopped)
A Q Q
LED
When 4th gear speed is

selected
LED
When 3rd gear speed is

selected
LED
When 2nd gear speed is

selected
LED
When 1st gear speed is

selected
Turn signal
LED
When turn signal lever and

hazard lamp switch signal is
input
Head lamp
high beam
LED
When head lamp is set to

high beam (when head lamp
is "ON" and dimmer switch
is "ON")
Engine oil level
Below set pressure (OPEN)

(detect time continues) and
after 30 seconds elapsed
since engine was started (no
detection time)
w Q Q
Normal oil pressure

(CLOSE)
Low oil pressure (OPEN)
w Q Q B@BAZG w Q Q B@BAZG
Normal
Water mixing with fuel
Normal oil level (CLOSE)
Radiator
coolant level
w Q Q
2G40ZG
Red
LED
LED
CA418
CA418
LED
2
Normal coolant level

(CLOSE)
Q B@BAZK
If low level is detected when

starting switch is turned "ON",
alarm is continued even after
engine is started until adequate
oil level is reached. Don't check
the oil level for 300 sec, after
stopping the engine.
LED
Low coolant level (OPEN)
10-910
Display of
message
Low oil level (OPEN)
16
Below set pressure (OPEN)

(detection time continues)
and 30 seconds after engine
is started (no detection time)
Hazard lamp operates when

starting switch is turned "OFF".
Red
Water
separator
Red
15
Engine oil
pressure
LED
When error occurs in

communication, condition is
held until starting switch is
turned "OFF".
Red
14
Brake oil
pressure
Green Green Green Green Green Green Orange Green
Travel
speed
range
selector
switch
position
LED
6
8
13
km/h or MPH
(setting of a desired value is
available from the machine
monitor)
Blue
Directional
lever
position
Normal oil pressure

(CLOSE)
Other
symbols
x 100 r/min
(setting of a desired value is
available from the machine
monitor)
LED
Items related
to gear
shifting
12
Display color
Converts travel speed pulse

into travel distance
Black
Odometer
Displays various codes and

items according to the machine
condition and switch operation.
Green
Green
Travel speed
36
Alarm buzzer
LCD
28
37
Individual display
Central warning
lamp
29
Remarks
Red
Unit
Engine is running
Operates when charging

normally at 1 : 1 to the clock
time
Service meter
Character
display
Operating condition
Display of
message
Device
Alarm buzzer
Item
Operating condition
Engine stopped
Individual display
Central warning
lamp
No.
Reset
Category
Detection
Detecting
time
(sec)
30
Q B@BCZK Q B@BCZK

Machine monitor
SEN03931-01
Clogging (CLOSE) (HST oil

temperature 50C or above
and no abnormality
detected)
10
When abnormality is
detected (clogging was
detected as engine was
stopped)
KEY

OFF
LED
Other
symbols
21
22
23
24
Quick coupler
operation
Cooling fan
reverse
rotation
Maintenance
Parking brake
reminder
Q AA1ANX
Released (CLOSE)
A Q Q
Temperature rise (oil

temperature: Min. 120C
(alarm)
Temperature rise (1. or 2.)

1. Oil temperature 130C or
above
2. Oil temperature 125C or
above and travel speed
35 km/h or above
w Q Q B@C6NS w Q Q B@C6NS
When abnormality is
detected (ground fault)
DGR2KB
DGR2KB
When abnormality is
detected (disconnection or
hot short-circuit)
DGR2KZ
DGR2KZ
Other than below
LED
LED
LED
When quick coupler is

disconnected
A Q Remarks A Q Remarks
Normal
Reverse
Q Remarks Q Remarks
Selecting reverse rotation
Ordinary
30 hours or less before

maintenance or
maintenance time
Other than below
When parking brake is left

unapplied (CLOSE)
Alarm buzzer is sounded when

connection of quick coupler is
reset. Error message is
simultaneously displayed on
the character display.
"PIN DISCONNECT"
Error message is displayed on

the character display as long
as reverse rotation of fan is
continued.
"COOLING FAN REVERSE"
Message is simultaneously
displayed on the character
display.
Error message is displayed on

the character display as long
as parking brake is left
unapplied.
The alarm continues as long as
starting switch is turned "OFF".
This function can be enabled
when "MECHA" is selected for
"7: PKG BRAKE" from the
"Option device selecting
function" of the machine
monitor.
To be released if the oil

temperature is detected
consecutively at lower than
125C for 5 sec.
LED
Display color
Display of
message
DHTCL6
Red
LED
Other than below
20
Operation (OPEN)
Engine is running, parking

brake operated and the
directional lever is at any
position other than "N"
Brake oil
temperature
Red
Parking brake
LED
Clogging (GND)
19
6091NX
Red
Air cleaner
clogging
DHTCL6
Red
Normal (OPEN)
18
Alarm buzzer
Orange
LED
Red
HST oil filter

clogging
Red
17
Remarks
Red
Normal (OPEN)
Engine is running
Individual display
Central warning
lamp
Operating condition
Display of
message
Device
Individual display
Central warning
lamp
Item
Reset
No.
Operating condition
Engine stopped
Alarm buzzer
Category
Detection
Detecting
time
(sec)
w Q Q Remarks
10-910

Machine monitor
SEN03931-01
LED
Steering oil
pressure
w Q Q AB00MA
When abnormality is
detected (unmatched engine
condition and the signal)
w Q Q

0.5
(*)
1
AB00L6
Display color
Display of
message
30
LED
Alarm buzzer
Engine is running, alternator

voltage is below the
specified level, and no
incoming ING-C is present.
Oil pressure normal (OPEN)
26
Red
Battery charge
circuit
If abnormality is detected when

starting switch is turned "ON",
alarm is continued even after
engine is started.

when "ADD" is selected for
"2: EMERG S/T" from the
"Optional device selecting
monitor.
*: The function is reset
immediately when engine is
stopped.
"2: EMERG S/T" from the
"Optional device selecting
monitor.
Low oil pressure (CLOSE)
Oil pressure normal (OPEN)

LED
Other than below
Red
Low oil pressure (CLOSE)
LED
0
When directional lever is

used
32
Directional
selector switch
actuation
Economy
operation
35
10-910
10
S mode
operation
Traction
control
operation
When directional selector

switch is used
Directional lever priority

caution
A w Q
A w Q
Directional selector switch

neutral caution
A w Q
A w Q
Other than below
Economy mode operation
LED
LED
Other than below

34
LED
S mode operation is
selected
Other than below
LED
Traction control operation is
turned on
Green
When preheater is turned on
Other
symbols
31

"3: FNR" from the "Optional
device selecting function" of
the machine monitor.
Not to be displayed when error
is made in communication.
Green
Preheating
DDS5L6
Green
30
w Q
Green
27
Emergency
steering
<Voltage hysteresis>
Judgment for Abnormal o
Normal: 12 V or above
Judgment for Normal o
Abnormal: 5 V or below
Red
25
Remarks
Green
Normal voltage
Engine is running
Individual display
Central warning
lamp
Operating condition
Display of
message
Device
Alarm buzzer
Item
Operating condition
Engine stopped
Individual display
Central warning
lamp
No.
Reset
Category
Detection
Detecting
time
(sec)
The lamp goes off when

traction control is reset from
max. traction switch. When
traction control is reset with
max. traction switch, the lamp
is lit again when directional
lever position is switched.

Machine monitor
SEN03931-01
Machine monitor operation switch
1. Machine monitor mode selector switch 1

10-910
11
SEN03931-01
Setting of machine monitor

Machine monitor
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
q
q
q
The machine monitor monitors the input and output signals constantly for troubleshooting for the system.
If each controller detects abnormality by the self-diagnosis, abnormality information is forwarded to the
machine monitor over the network.
Abnormality information can be checked on the character display using the failure code display mode of
the machine monitor.
10-910
12

Machine monitor
SEN03931-01
Character display function

q
q
Machine monitor display and setting can be changed by using the character display.
The range where operator is enabled to operate is within the portion of the "Operator mode" in the figure
below.
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".
10-910
13
SEN03931-01

Machine monitor
Operator mode functions
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 character 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

Machine monitor
SEN03931-01
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 seconds 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 failure 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 failure code screen.
10-910
15
SEN03931-01

Machine monitor
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

Machine monitor
SEN03931-01
Service mode functions

q
q
Procedure for switching to Service Mode

1. Checking of the screen display
Check that the character display is set to the
1st layer screen in the operator mode.
2.
The machine monitor is provided with service mode function for the ease of troubleshooting for the controllers on the network (including the machine monitor itself).
Initial setting of the sensors and optional setting can be made in the service mode of the machine monitor.
3.
ID input and confirmation

Operate the machine monitor mode selector
switches 1 and 2 and enter ID. (ID: 6491)
Display of ID input initial screen

Pressing "u" switch and "<" switch simultaneously for 5 seconds or more displays the ID
entry initial screen.
a Pressing down the 2 switches for 5 seconds or more makes the entire screen
blank. As this state is recognized, release
the switches.
1)
2)
3)
4)
The cursor (C) is located at the highestorder digit. Pressing "<" or ">" switch
changes the value of this digit in the range
of "0" to "9".
Press "U" switch at the target value to
validate it.
a The cursor moves to the 2nd digit
position.
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 highestorder 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.
If ID is acknowledged upon confirming the
4th digit, the screen changes to the "Electrical system failure history" selector
screen.
10-910
17
SEN03931-01

Machine monitor
Service mode menu
a
a
a
Pressing "<" or ">" switch on the menu screen switches individual menus of the service mode sequentially and endlessly.
Pressing "U" switch on the target menu screen changes the screen to the detailed screen of the same
menu.
Pressing "t" switch on the menu screen returns the screen to the 1st layer of the operator mode.
10-910
18

Machine monitor
SEN03931-01
Electrical system failure history display

function (ELECTRIC FAULT)
Real-time monitoring function (REAL-TIME

MONITOR)
"**" field displays total number of the failure

history currently recorded. (max. 20 histories to
be stored)
The history is used to check on the electrical

system failures of each controller saved in the
machine monitor. After repairing the failure
content and verifying normal function, the failure history may be erased.
For the operating procedure of this function,
see "Special functions of machine monitor
(EMMS)" in Testing and adjusting.
This function is used to check on the input/output signals, etc. each controller on the network
recognizes.
Mechanical system failure history display

function (MACHINE FAULT)
Engine reduced-cylinder function (CYLINDER

CUT-OUT)
"**" field displays total number of the failure

history currently recorded. (max. 20 histories to
be stored)
The history is used to check on the mechanical
system failures of each controller saved in the
machine monitor.
This function is used for the purpose of specifying cylinder having defective combustion by
stopping fuel injection to each cylinder from the
fuel injector.
10-910
19

Machine monitor
SEN03931-01
No injection cranking function (NO INJECTION)
Before restarting engine after a long-term storing of the machine, this function is used to
lubricate the engine internally.
Adjustment function (TUNING)
This function is used for correcting and adjusting the installation errors and manufacturing
dispersion of the sensors, solenoid valves, etc.
Function for changing control characteristics is
provided on user request.
These functions are also used when sensors,
valves and controllers are replaced or added.
10-910
20
Maintenance monitoring function (MAINTENANCE MONITOR)
This function is used for changing the filter and

oil replacement timing and making ON/OFF
selection of this function.
Operating information display function (OPERATION INFO)
This function is used for displaying fuel consumption per operating hour.

Machine monitor
Optional device selecting function (OPTIONAL

SELECT)
SEN03931-01
Model selection function (MACHINE)
q
q
This function is used for verifying the installed

state of optional devices or when changing
their setting.
This function is also used for installing or
removing optional devices.
Machine serial number input function

(MACHINE No. SET)
a
a
Initialize function (INITIALIZE)
q
q
This function is used for displaying or entering

the serial number of machine.
Serial number of the set machine is used for
controlling the machine.
This function is used for displaying or changing

the setting of model information (machine
name).
The figure shows when "WA250" is selected.
This function is used to set the machine monitor to the state set when delivered.
Since this function is specially handled by the
factory, no modification is allowed.
10-910
21

Machine monitor
SEN03931-01
AMP070-20P[CN-L24]
Pin No.
Specifications
I/O
Group
Form of use
Signal name
(NC)
(NC)
(NC)
NSW power supply (+24 V)
Constant power
supply (+24 V)
Constant power
supply (+24 V)
SW power supply (+24 V)
Power supply
(+24 V)
Power supply
(+24 V)
(NC)
GND
GND
GND
10
GND
GND
GND
11
D_OUT_3
(+24 V, sink 200 mA)
D/O sink
ECSS relay
12
D_OUT_2
(+24 V, sink 200 mA)
D/O sink
Back-up lamp
13
(NC)
14
D_OUT_0
(+24 V, sink 200 mA)
D/O sink
Alarm buzzer
15
(NC)
16
(NC)
17
GND
GND
GND
18
GND
GND
GND
19
GND
GND
GND
20
GND
GND
GND
10-910
22
Remarks
If equipped

Machine monitor
SEN03931-01
AMP070-18P(1)[CN-L25]
Pin No.
Specifications
I/O
Group
Form of use
Signal name
Remarks
D_IN_0
(24 V, 5 mA)
D/I (+24 V)
Head lamp
D_IN_2
(24 V, 5 mA)
D/I (+24 V)
Starting switch C signal
(NC)
D_IN_6
(24 V, 5 mA)
D/I (+24 V)
Quick coupler
If equipped
D_IN_8
(24 V, 5 mA)
D/I (+24 V)
ECSS switch
If equipped
(NC)
D_IN_12
(NSW24 V, 5 mA)
D/I (+24 V)
Turn signal lamp, right
D_IN_14
(NSW24 V, 5 mA)
D/I (+24 V)
U switch
GND
GND
Signal GND
10
D_IN_1
(24 V, 5 mA)
D/I (+24 V)
Cooling fan automatic reverse

rotation switch (manual)
11
(NC)
12
(NC)
13
(NC)
14
D_IN_9
(24 V, 5 mA)
D/I (+24 V)
Cooling fan automatic reverse

rotation switch (automatic)
15
(NC)
16
D_IN_13
(NSW24 V, 5 mA)
D/I (+24 V)
Turn signal lamp, left
17
D_IN_15
(NSW24 V, 5 mA)
D/I (+24 V)
t switch
18
A_IN_0
(0 30 V)
A/I
Alternator L signal
AMP070-12P(1)[CN-L26]
Pin No.
Specifications
I/O
Group
Form of use
Signal name
D_IN_16
(24 V/GND, 5 mA)
D/I (GND)
Brake oil pressure
(NC)
D_IN_20
(24 V/GND, 5 mA)
D/I (GND)
Air cleaner clogging
D_IN_22
(24 V/GND, 5 mA)
D/I (GND)
Traction control switch (S mode)
D_IN_24
(24 V/GND, 5 mA)
D/I (GND)
HST oil filter clogging
GND
GND
Sensor ground
D_IN_17
(24 V/GND, 5 mA)
D/I (GND)
ECSS cut off switch
D_IN_19
(24 V/GND, 5 mA)
D/I (GND)
(service mode 2 and 3)
D_IN_21
(24 V/GND, 5 mA)
D/I (GND)
ECSS cutoff switch dummy
10
(NC)
11
D_IN_25
(24 V/GND, 5 mA)
D/I (GND)
(optional switch)
12
A_IN_1
(0 30 V)
A/I
Clearance lamp and tail lamp
Remarks
If equipped
If equipped
10-910
23

Machine monitor
SEN03931-01
AMP070-18P(2)[CN-L27]
Pin No.
Specifications
I/O
Group
Form of use
Signal name
D_IN_26
(24 V/GND, 5 mA)
D/I (GND)
Parking brake
D_IN_28
(24 V/GND, 5 mA)
D/I (GND)
Parking brake left-unapplied

prevention
D_IN_30
(24 V/GND, 5 mA)
D/I (GND)
Normal emergency steering
(NC)
D_IN_34
(24 V/GND, 5 mA)
D/I (GND)
Dimmer switch
D_IN_36
(24 V/GND, 5 mA)
D/I (GND)
Parking brake dummy
D_IN_38
(24 V/GND, 5 mA)
D/I (GND)
< switch
(NC)
GND
GND
GND
10
D_IN_27
(24 V/GND, 5 mA)
D/I (GND)
Coolant level
11
D_IN_29
(24 V/GND, 5 mA)
D/I (GND)
Engine oil level
12
(NC)
13
(NC)
14
D_IN_35
(24 V/GND, 5 mA)
D/I (GND)
Parking brake left-unapplied

prevention dummy
15
D_IN_37
(24 V/GND, 5 mA)
D/I (GND)
> switch
16
D_IN_39
(24 V/GND, 5 mA)
D/I (GND)
Operation of emergency steering
17
(NC)
18
(NC)
Remarks
If equipped
If equipped
AMP070-12P(2)[CN-L28]
Pin No.
Specifications
I/O
Group
Form of use
Signal name
A_IN_2
(high-resistance input)
A/I
Fuel level sensor
A_IN_4
A/I
HST oil temperature sensor
(NC)
(NC)
(NC)
GND
GND
GND
A_IN_3
A/I
Brake oil temperature sensor
(NC)
(NC)
10
(NC)
11
GND
GND
(GND)
12
(NC)
10-910
24
Remarks

Machine monitor
SEN03931-01
AMP070-12P(3)[CN-L29]
Pin No.
Specifications
I/O
Group
Form of use
Signal name
(NC)
(NC)
CAN (+)
I/O
CAN
CAN (+)
(NC)
(NC)
GND
GND
GND
(NC)
CAN ()
I/O
CAN
CAN ()
(NC)
10
(NC)
11
(NC)
12
(NC)
Remarks
AMP070-14P[CN-L30]
Pin No.
Specifications
I/O
Group
Form of use
Signal name
(NC)
(NC)
(NC)
(NC)
(NC)
(NC)
(NC)
(NC)
(NC)
10
(NC)
11
(NC)
12
(NC)
13
(NC)
14
(NC)
Remarks
10-910
25

Machine monitor
SEN03931-01
AMP040-8P
Pin No.
Specifications
I/O
Group
Form of use
Signal name
Remarks
(NC)
Do not connect wiring

harness on machine
(NC)

harness on machine
(NC)

harness on machine
(NC)

harness on machine
(NC)

harness on machine
(NC)

harness on machine
(NC)

harness on machine
(NC)

harness on machine
Setting switches (On circuit board)

Switch
No.
Specifications
I/O
Group
Form of use
Signal name
16 Posi rotary switch 1
(spare)
(spare)
(spare)
26 Posi DIP switch 1
(spare)
(spare)
(spare)
(spare)
(spare)
(spare)
(spare)
(spare)
Remarks
10-910
26

Machine monitor
SEN03931-01
10-910
27
SEN03931-01

2009 KOMATSU
All Rights Reserved
10-910
28
SEN03932-02
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up

10

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
Multi-function knob........................................................................................................................................ 33
Max. traction switch ...................................................................................................................................... 34
Sensor........................................................................................................................................................... 35
10-920

Electrical system (HST controller system)
SEN03932-02

a
Except where otherwise specified, the displayed travel speed in this document represents the one when
20.5-25 tire is worn.
Ao
o A HST motor 1 solenoid
Variable shift control switch
Ao
o D HST motor 2 solenoid relay
Traction control switch
Do
o A Clutch solenoid
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)
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
Accelerator pedal angle (Eng_con)
Co
Coolant temperature (Eng_con)
Co
Boost temperature (Eng_con)
Co
Co
Monitor display information (Eng_con)

o C (Failure code, real-time monitor, pilot lamp,
alarm buzzer, etc.)
o C Travel speed (Mon)
o C ECSS operation command (Mon)
CAN output
Monitor display information (Eng_con)

(Failure code, real-time monitor, pilot lamp,
alarm buzzer, etc.)
Solenoid output
Travel speed range selector switch
HST controller
Sensor input
Operating switch input
Input and output signals diagram
o C Back-up lamp operation command (Mon)
CAN input
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)
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

SEN03932-02
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
speed
range
Travel speed range

(km/h)
Clutch solenoid
output
HST motor 1
solenoid output
HST motor 2
solenoid output
Variable shift control

signal input voltage
(V)
0 13
1st
(depends on the variable

shift control signal)
ON
MAX MID
Fixed to MAX (ON)
0.9 4.1
2nd
0 13
ON
MAX MID
Fixed to MAX (ON)
3rd
0 18.7
ON, OFF
MAX 0
Fixed to MAX (ON)
4th
0 38
ON, OFF
MAX 0
Fixed to MAX
Variable (ON, OFF)

and travel speed (A) for starting transfer clutch
switching modulation
Transfer clutch
Engaged o
Disengaged (B)
Disengaged o
Engaged (C)

0 65
65 90
90 100
8 km/h
8 10 km/h
10 km/h
7 km/h
7 9 km/h
9 km/h

and travel speed (A) for switching HST motor 2
capacity
HST motor 2
capacity
Max. fixed (D)
Free (E)

0 65
65 90
90 100
8 km/h
8 10 km/h
10 km/h
9 km/h
9 11 km/h
11 km/h
10-920
SEN03932-02
1. HST pump
2. HST motor 1
3. HST motor 2
4. Transfer clutch


6. HST motor 1 solenoid valve
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

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

SEN03932-02
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
released.
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
continued.
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
slippery 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 performance.
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".
Switch
position
1
(OFF)
Features
Pilot lamp Traction level
OFF
2
(ON)
2B
2C
3
(S mode)
3
(ON)
Material
Road
condition
Guideline
1
2A
2
(ON)
Traction
Suitable for loading work. Improves work

efficiency and provides antislip by selecting
Un-slippery traction level depending on material and
I
road conditions.
O
Slippery
Select when operating with the special
attachment which requires small traction
force.
Provides the best driving force on very
Select when the machine tends to slip when
slippery road surfaces covered by snow,
forwarding, such as on snow or sand
sand, etc. Prevents the tires from slipping
covered road surface.
to facilitate work.
Powerful
I
O
Soft
Hard-packed
I
O
Loose
10-920
SEN03932-02

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"
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 reduce 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.
As clockwise turning of the variable shift control switch (2) is continued, the traction force
approaches the maximum traction force being
set from the "Traction level selecting function"
of the machine monitor.
It is possible to obtain the maximum traction
force, which has been set from the traction
control switch and "Traction level selecting
function" of the machine monitor, by turning the
variable shift control switch (2) fully to the right.
10-920

SEN03932-02
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
10-920

SEN03932-02
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
travel, 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
Switch position
State of transfer
before gear
clutch after gear shift
shift
1st
2nd
Behavior after gear shift

Switch
position after
gear shift
Actual speed
range after
gear shift
2nd
2nd
3rd
3rd
4th
4th
Connected
Connected
Connected
3rd
(*1)
Other than the
connected state
Connected
4th
(*1)
Other than the
connected state
1st
1st
3rd
3rd
4th
4th
1st
1st
2nd
2nd
4th
4th
1st
3rd
2nd
3rd
4th
4th
1st
1st
2nd
2nd
3rd
3rd
1st
3rd
2nd
3rd
3rd
3rd
Display of
message
Remarks
Not displayed
Gear shift available independent

of traveling speed
Not displayed
Gear shift available independent

of traveling speed
Not displayed
Displayed
Gear shift to 1st or 2nd becomes

available only when the clutch is
engaged.
Not displayed
Not displayed
Displayed
Gear shift to 1st or 2nd becomes

available only when the clutch is
engaged.
Not displayed
*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
traveling at 7 up to 9 km/h.
Relationship between accelerator pedal angle and travel speed (A) for starting transfer clutch switching modulation
Transfer clutch
Engaged o
Disengaged (B)
Disengaged o
Engaged (C)
10-920

0 65
65 90
90 100
8 km/h
8 10 km/h
10 km/h
7 km/h
7 9 km/h
9 km/h

SEN03932-02
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
function 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 maximum if the travel speed goes beyond 14 km/h.
Travel speed control function
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
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.
q
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
motor 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
Neutralizer function
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
q
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.
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.
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.
For the setting procedure, see "Special functions of machine monitor (EMMS)" in Testing and adjusting.
10-920
SEN03932-02

Cooling fan control function
1. HST controller
2. Machine monitor
3. Engine controller
4. Cooling fan pump
5a. Cooling fan motor flow rate control EPC valve
5b. Cooling fan reverse solenoid valve
6. Cooling fan reverse switch
9. Cooling fan reverse solenoid valve relay
10. HST oil temperature sensor
11. Boost pressure and oil temperature sensor
12. Coolant temperature sensor
13. Engine speed sensor
14. Engine
15. Radiator
10-920
10

HST controller
a. CAN signal
b. Cooling fan motor flow rate control signal
c. Cooling fan reverse signal
Machine monitor
d. Cooling fan automatic reverse signal
e. Cooling fan manual reverse signal
f. CAN signal
g. "U" switch signal
h. "t" switch signal
i. ">" switch signal
j. "<" switch signal
k. HST oil temperature signal
Engine controller
l. CAN signal
m. Boost pressure and temperature signal
n. Engine speed signal
o. Coolant temperature signal

SEN03932-02
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
temperature 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.)
10-920
11
SEN03932-02

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 following table is met.
Condition 1
Starting switch is turned "ON".
Condition 2
Engine speed is 700 rpm or above.
Condition 3
Engine is rotating forward.

[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

SEN03932-02
Fan reverse rotation function

q
As the fan reverse rotation switch is pressed for cleaning of the radiator core, the cooling fan reverse
rotation 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
(*1)
Engine speed over 500 rpm and below 1,200 rpm.

[above is required to prevent generation of peak pressure in the process of switching the direction.]
Coolant temperature is below 102C.
[above is required to prevent overheating.]
HST oil temperature is below 100C.
Boost air temperature is below 80C.
30 seconds minimum have elapsed since the engine is started (since the engine speed reached
500 rpm or above).
[above is required to secure the oil to be supplied to the brake accumulator.]
Condition 3
Condition 4
Condition 5
Condition 6
The fan rotation is switched from "reverse" to "forward" if any of the following conditions is met.
Condition 1
(*1)
Condition 2
(*1)
While the fan is rotating reverse, the fan reverse switch was again set to "MANUAL" and the engine
speed went to below 1,200 rpm.
After the fan rotated in the reverse direction for 10 minutes, the engine speed went to less than
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.
10-920
13

SEN03932-02
4.
Fan automatic reverse rotation function

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
Condition 2
Condition 3
Condition 4
Condition 5
Condition 6
The fan reverse rotation switch is set to "AUTO".

Coolant temperature is below 102C.
HST oil temperature over 13C and below 100C.
[the upper limit of 95C is required to prevent overheating.]
Boost air temperature is below 80C.
30 seconds minimum have elapsed since the engine is started (since the engine speed reached
500 rpm or above).
[above is required to secure the oil to be supplied to the brake accumulator.]
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.
5.
Condition 1
Set the fan reverse rotation swith 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.
Adjustment of the automatic fan switching cycle to reverse rotation and duration
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
operation" 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
adjusting.
10-920
14

SEN03932-02
10-920
15
SEN03932-02
System circuit diagram
a

Items marked with "*1" in drawing may or may not installed.
10-920
16

SEN03932-02
10-920
17

HST controller
SEN03932-02
HST controller

DEUTSCH-40P [CN-HST]
Pin
No.
Signal name
Input/Output
signal
Pin
No.
Signal name
Input/Output
signal
VB (controller power)
Input
21 GND (controller GND)
Starting switch ACC signal
Input
22 HST sensor power 5V
Input
Wake up
Input
23 Travel speed adjusting dial
Input
Directional selector switch F
Input
24 Directional selector switch R
Input
Directional lever N
Input
25 Directional selector switch operating switch
Input
Parking brake lever intermediate switch
Input
26 Speed sensor A
Input
HST controller power holding relay
NC
Clutch solenoid
Output
10 HST pump F solenoid
27 HST motor 2 solenoid relay

28 CAN0_H
Output
Input/Output
Output
29 Cooling fan motor flow rate control EPC
Output
30 VIS (solenoid power)
Output
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
17 HST safety relay

18 NC
Output
Input
37 Cooling fan motor reverse rotation solenoid relay

38 CAN0_L
Input/Output
19 HST motor 1 solenoid
Output
39 Travel speed range selector switch
20 HST pump R solenoid
Output
40 SOL_COM (solenoid common GND)
10-920
18
Output
Input

HST controller
SEN03932-02
10-920
19

ECSS system
SEN03932-02
ECSS system
(If equipped)
a ECSS: Abbreviation for Electronically Controlled Suspension System
1. HST controller
2. Machine monitor
3. ECSS switch
4. ECSS relay
5. ECSS solenoid valve
6. Speed sensor
7. Bucket tilt PPC oil pressure switch
8. Lift arm lower PPC oil pressure switch
HST controller
a. Travel speed signal A
b. Travel speed signal B
c. CAN signal
Machine monitor
d. CAN signal
e. ECSS switch "ON" signal
f. ECSS operation signal
g. ECSS cut off signal
h. ECSS cut off (dummy) signal
10-920
20
Outline
q
When the machine travels at high speed, the
damping effect of the accumulator charged
with high-pressure gas and the automatic control of the lift cylinder circuit relief pressure
under each travel condition damp the vertical
movement of the work equipment and reduce
rocking of the chassis. As a result, the operator
comfort is improved, spillage of material is prevented, and the working efficiency is improved.
Setting method
q
The ECSS can be enabled only when "ADD" is
selected for "5: E.C.S.S." 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.

ECSS system
SEN03932-02
Operation
q
The operating condition of ECSS is as follows.
ECSS switch
Travel speed [km/h]
OFF
0 Max.
(*2) Max. 4
(*1) Min. 5
ON
ECSS operation
signal
The operating condition of PPC oil pressure

switch is as follows.
OFF
ON
PPC oil pressure switch

operating point
Operating oil pressure
[MPa{kg/cm2}]
ECSS switching point
Travel speed [km/h]
(*2)
4
(*1)
5
0.29
{3}
0.49
{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 operation 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 Testing and adjusting.
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21
SEN03932-02

KOMTRAX system
KOMTRAX system
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

KOMTRAX system
SEN03932-02
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]
Pin No.
Signal name
Input/Output
signal
Pin No.
Signal name
Input/Output
signal
NC
21
Operation mode selection 1
Input
NC
22
Operation mode selection 2
Input
NC
23
NC
NC
24
NC
NC
25
NC
NC
26
NC
CAN0_L
Input/Output
27
Starting switch C signal
Input
CAN0_H
Input/Output
28
Alternator L signal
Input
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 supply GND
18
NC
38
Power supply GND
19
NC
39
Constant power supply (24 V)
Input
20
Immobilize signal
Output
40
Constant power supply (24 V)
Input
Outline
q
The KOMTRAX controller can send information via wireless communication antenna,
acquiring various information of the machine
from the network signal in the machine and the
input signal. Also, the controller incorporates
CPU (Central Processing Unit) and provides
the wireless communication function and the
GPS (Global Positioning System) function.
There are the LED lamp and the 7-segment

indicator lamp in the display area, and these
lamps are used for the testing and the troubleshooting.
KOMTRAX terminal can be used only in the
countries specified by the communication contract.
10-920
23

Engine starting circuit
SEN03932-02
1. Battery
2. Battery relay
3. Slow-blow fuse
4. Fuse box 1
5. Fuse box 2
6. Starting switch
7. Directional lever
8. Neutral safety relay
9. KOMTRAX engine cut-out relay
10. HST controller power holding relay
11. Starting motor safety relay
12. Starting motor
13. Alternator
14. HST controller
16. Machine monitor
17. KOMTRAX terminal
18. Engine controller cut-out relay
19. CAN resistor
20. Directional selector switch operating switch
10-920
24
Function
1. The neutral safety circuit is employed to
secure safety when the engine is started.
q
The engine can not be started while the
directional lever is at any position other
than N (neutral).
q
When the directional selector switch operating switch is turned "ON", the directional
lever and the directional selector switch
must be at "N (neutral)" to start the
engine.
2.
The KOMTRAX engine cut-out circuit is

employed to disable the engine from starting
when the KOMTRAX terminal receives an
engine cut command issued through external
operation.
(if equipped)

SEN03932-02
Operation
1. When starting switch is turned "ON"
q
As the starting switch is turned "ON", terminals 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 directional lever to the neutral safety
relay to activate it.
q
When the directional selector switch is
used (when the directional selector switch
operating switch is turned "ON"), if both
the directional lever and directional selector switch are at "N (neutral)" at this point,
the neutral safety relay is activated.
3.
When starting switch is set to "START"

q
As the starting switch is set to "START",
the current flows through the starting
switch terminal C, KOMTRAX engine cutout relay and neutral safety relay to the
starting motor safety relay to start the
engine.
q
When the directional lever is set to any
position other than "N (neutral)", the neutral safety relay is not activated and interrupts the engine startup.
q
When the directional selector switch is
used (when the directional selector switch
operating switch is turned "ON"), if either
of the directional lever and the directional
selector switch is not at "N (neutral)", the
neutral safety relay is not activated and
thus the engine is not started.
q
As KOMTRAX terminal receives the externally applied engine cut-out command,
KOMTRAX engine cut-out relay is activated, shutting down the circuit from the
starting switch terminal C to the starting
motor safety relay. Thus, engine start-up
becomes unavailable.
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25
SEN03932-02
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-out relay working to maintain the current flow to the engine
controller 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 alternator 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

Preheating circuit
SEN03932-02
Preheating circuit
1. Battery
2. Battery relay
3. Slow-blow fuse
4. Fuse box 1
5. Starting switch
7. Machine monitor
8. Electrical intake air heater relay
9. Electrical intake air heater
10. Boost pressure and temperature sensor
Operation
q
Set the starting switch to "ON" to start the
engine controller. At this time, if intake air temperature is -4C or below, the engine controller
starts up the electrical intake air heater immediately after the starting switch is turned "ON"
to initiate preheating by the electrical intake air
heater.
q
The preheating time is set as shown below.
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
preheater pilot lamp of the machine monitor
and starts preheating of intake air with the
electrical intake air heater.
The engine controller sets the preheating duration 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
preheating is continued. Keep the starting
switch in the "ON" position during this time.
Setting the starting switch to "START" from this
state resets preheating.
10-920
27

Engine output derating function
SEN03932-02
Engine output derating function
If the engine controller detects a failure, it protects the engine by derating the engine torque
or speed.
Following figure shows the engine torque performance when the torque was derated.
A:
Derated to approximately 30% of the maximum

torque point
Derated to approximately 50% of the rated output point
Automatic warm-up function

q
B:
A:
Following figure shows the engine torque performance when the engine speed was derated.
When starting the engine in a cold district, this

function warms it up by increasing the engine
low idle speed.
If the coolant temperature is below 20C at
starting of the engine, this function increases
the low idle speed to 1,000 rpm. The condition
required for increasing the low idle speed
depends on the coolant temperature as shown
in the figure below.
The automatic warm-up function is reset and the

engine speed returns to 825 rpm as any of the following conditions is met.
The coolant temperature reaches 30C or
Condition 1 above while the automatic warm-up
function 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
automatic warm-up function restarts.)
Derated near to the engine speed at maximum

torque point
10-920
28

Automatic warm-up function
SEN03932-02
10-920
29
SEN03932-02
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
10. HST pump forward solenoid valve
11. HST pump reverse solenoid valve
10-920
30

SEN03932-02
Operation
Starting switch position
OFF
ON
State of engine
Parking brake lever area
Parking brake lever
intermediate switch (1)
Parking brake lever bottom
switch (2)
[for parking brake pilot lamp
operation]
Parking brake reminder
caution lamp
(Alarm buzzer)
Stopped
Free
Mid
Close
Close
Parking brake pilot lamp
Lock
Open
Open
[*1], [*2]
ON
(Sounded)
OFF
(Reset)
OFF
When the parking brake lever is set to "Free"

position
q
When the parking brake lever is set to the free
position, the intermediate switch (1) and bottom switch (2) are both closed.
q
The parking brake pilot lamp goes off independent of the given state.
q
The parking brake is released.
*1: When the starting switch is turned from "ON" to
"OFF":
q
The parking brake reminder caution lamp turns
on and the alarm buzzer sounds.
q
The HST controller power holding relay
remains turned on, conducting current to the
HST controller and maintaining the HST motor
1 solenoid valve and clutch solenoid valve
being activated. Thus, the machine is protected from slipping through a slope.
*2: If the parking brake lever is set to any position
other than "Lock" when the starting switch is at
"OFF", the parking brake reminder caution
lamp remains turned off and the alarm buzzer
is also not activated. And HST motor 1 solenoid valve and clutch solenoid valve remain
inactivated.
Running
Free
Mid
Lock
Close
Close
[*1]
ON
(Sounded)
OFF
Open
Open
Free
Lock
Close
Close
Open
Open
OFF
(Reset)
OFF
(Reset)
ON
Mid
OFF
ON
When the parking brake lever is set to "Mid"

position
q
When the parking brake lever is set to the mid
position, the bottom switch (2) is open but
intermediate 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
forward and reverse solenoid valves of HST
pump is stopped to prevent dragging of the
parking brake. And, at the same time, the
directional lever and the directional selector
switch are disabled to turn on the machine
travel in both the forward and reverse direction.
*1: When the starting switch is turned from "ON" to
"OFF":
q
The parking brake reminder caution lamp turns
on and the alarm buzzer sounds.
q
The HST controller power holding relay
remains turned on, conducting current to the
HST controller and maintaining the HST motor
1 solenoid valve and clutch solenoid valve
being activated. Thus, the machine is protected from slipping through a slope.
When the parking brake lever is set to "Lock"
position
q
Pulling the parking brake lever fully opens both
the intermediate switch (1) and bottom switch
(2).
q
The parking brake pilot lamp comes on only
when the starting switch is "ON".
q
The parking brake reminder caution lamp goes
off independent of the given state.
q
As bottom switch (2) opens, the output to the
forward and reverse solenoid valves of HST
pump is stopped to prevent dragging of the
parking brake. And, at the same time, the
directional lever and the directional selector
switch are disabled to turn on the machine
travel in both the forward and reverse direction.
q
The parking brake is activated.
10-920
31
SEN03932-02
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
"Release" position
q
If the quick coupler attachment switch (1) is set
in the "Release" position, quick coupler solenoid valve (2) is energized.
If the work equipment (bucket) control lever is
moved to the tilt side, the oil flows into the
head side of coupler plunger (3). Then, coupler
plunger (3) is retracted and the attachment and
coupler are released.
10-920
32
When quick coupler attachment switch is in

"Connect" position
q
If the quick coupler attachment switch (1) is set
in the "Connect" position, quick coupler solenoid valve (2) is de-energized.
If the work equipment (bucket) control lever is
moved to the tilt side, the oil flows into the bottom side of coupler plunger (3). Then, coupler
plunger (3) is extracted and the attachment
and coupler are connected.

Multi-function knob
SEN03932-02
Multi-function knob

2. Max. traction switch
3. Option switch [Reserved]
Function
q
Directional selector switch (1) is an alternate
type. Its control signal sent to the HST controller causes switching between the forward and
reverse 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
33
SEN03932-02
Max. traction switch

Max. traction switch
2-lever type
(If equipped)
1.
2.
3.
4.
Switch A (white wiring harness)

Switch B (yellow wiring harness)
Spring
Wiring harness
10-920
34
Function
q
These switches are installed on the knob of the
lift arm control lever. Switch A (1) functions as
the max. traction switch and switch B (2) does
not function.
q
Both of switch A (1) and switch B (2) are of
momentary type, that is, their contacts are
closed only while they are pressed.

Sensor
SEN03932-02
Sensor
Speed sensor
1. Hall IC
2. Circuit board
3. O-ring
4. Housing
5. Heat shrink tube

6. Protective tube
7. Lead wire
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.
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35

Sensor
SEN03932-02
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
hydraulic piping and front axle, respectively. They generate the signal for the change in temperature as
variation in the resistance of the thermistor.
1. Sensor
2. Lead wire
3. Connector
Function
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

Sensor
SEN03932-02
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
pressure goes beyond the specified level, the switch is set to "ON".
Coolant level sensor
1. Float
2. Sensor
3. Connector
4. Sub-tank
Function
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".
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37

Sensor
SEN03932-02
Fuel level sensor
1.
2.
3.
4.
Connector
Float
Arm
Body
5. Spring
6. Contact
7. Spacer
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

Sensor
SEN03932-02
Accelerator pedal sensor
1. Pedal
2. Connector
3. Sensor
Output characteristics
Function
q
This sensor is installed on the surface of the
floor. It outputs the accelerator signal or idle
validation signal depending on the accelerator
pedal pressing angle.
Accelerator signal
Magnitude of the accelerator pedal displacement being detected by the sensor is output in
variable voltage from No. 2 pin.
Idle validation signal

The sensor detects the accelerator pedal operation. As the accelerator pedal is released, it
outputs 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.
10-920
39

Sensor
SEN03932-02
Air cleaner clogging sensor
1. Indicator
2. Spring
3. Adapter
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
2. Tube
3. Sensor
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

Sensor
SEN03932-02
Boom kick-out proximity switch

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

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
positioned on the detector plane, the switch lights up the operation indication lamp and turns itself "ON".
10-920
41
SEN03932-02

2009 KOMATSU
All Rights Reserved
10-920
42
SEN03933-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
20 Standard value table
20

Standard service value table for engine .......................................................................................................... 2
Standard service value table for chassis......................................................................................................... 3
20-100

Standard service value table for engine
SEN03933-00
Standard service value table for engine
Machine model
WA320-6
Engine
Item
Engine speed
SAA6D107E-1
Measurement conditions
High idle (*)
Standard value for

new machine
Service limit value
2,250 50
2,250 50
825 25
825 25
Max. 550
600
kPa
{mmHg}
Min. 127
{Min. 950}
100
{750}
Unit
rpm
Low idle (*)
Exhaust temperature
All revolution ranges
(Turbocharger outlet tem(Atmospheric temperature: 20C)
perature)
Intake air pressure
(Boost pressure)
At rated output
At aftercooler outlet side
Exhaust gas color
At rated output
Engine coolant temperaPollution
ture: Within operating range At sudden acceleration level %
Valve clearance
Normal temperature
Blow-by pressure
At rated output
Engine coolant temperature: Within operating
range
Oil pressure
At high idle
SAE0W30E0S
Engine coolant temperature: Within operating range SAE0W40E0S
SAE10W30DH
At low idle
SAE15W40DH
Engine coolant temperaSAE30DH
ture: Within operating range
Oil temperature
Belt tension
20-100
Intake valve
Exhaust valve
All engine speed ranges (Inside oil pan)

Deflection under finger presIdler pulley
sure of approx. 58.8 N
crankshaft pulley
{approx. 6 kg}
Deflection under finger
pressure of approx. 98 N
{approx. 10 kg}
Air conditioner compressor crankshaft

pulley
mm
kPa
{mmH2O}
MPa
{kg/cm2}
Max. 12
22
Max. 25
35
0.25 0.05
0.152 0.381
0.51 0.05
0.381 0.762
Max. 0.98
{Max. 100}
1.96
{200}
Min. 0.29
{Min. 3.0}
0.25
{2.5}
Min. 0.10
{Min. 1.0}
0.07
{0.7}
80 110
Min. 120
Auto-tensioner
Auto-tensioner
11 14.5
11 14.5
mm

Standard service value table for chassis
SEN03933-00
Speed switch (Dial switch)
Directional lever
Category
Machine model
Item
WA320-6
13.7 {1.4}
5.9 (+5.9/0)
{0.6 (+0.6/0)}
13.7 {1.4}
45 10
45 20
45 10
45 20
7.8 4.9
{0.8 0.5}
15.7
{1.6}
7.8 4.9
{0.8 0.5}
15.7
{1.6}
3rd 4th
7.8 4.9
{0.8 0.5}
15.7
{1.6}
1st 2nd
30 5
30 10
N
{kg}
Operating effort
N
REVERSE
N
FORWARD
Engine stopped
Measure at 10 mm from top of lever
mm
N
REVERSE
1st 2nd
Operating effort 2nd 3rd
Travel
2nd 3rd
Engine stopped
Measure at 10 mm from end of switch
knob
Engine stopped
N
{kg}
deg.
30 5
30 10
30 5
30 10
HOLD o
RAISE
10.8 (+4.9/0)
{1.1 (+0.5/0)}
16.7
{1.7}
RAISE o
HOLD
7.8 (+4.9/0)
{0.8 (+0.5/0)}
11.8
{1.2}
HOLD o
LOWER
10.8 (+4.9/0)
{1.1 (+0.5/0)}
16.7
{1.7}
20.6 (+4.9/0)
{2.1 (+0.5/0)}
31.4
{3.2}
FLOAT o
HOLD
20.6 (+4.9/0)
{2.1 (+0.5/0)}
31.4
{3.2}
HOLD o
DUMP
12.3 (+4.9/0)
{1.25 (+0.5/0)}
18.6
{1.9}
HOLD o
TILT
10.8 (+4.9/0)
{1.1 (+0.5/0)}
16.7
{1.7}
TILT o
HOLD
7.8 (+4.9/0)
{0.8 (+0.5/0)}
11.8
{1.2}
HOLD o
RAISE
37 9
37 9
HOLD o
LOWER
37 9
37 9
13.5 9
13.5 9
HOLD o
DUMP
50.5 9
50.5 9
HOLD o
TILT
37 9
37 9
3rd 4th
Lift arm
Operating effort
Work equipment control lever
Standard value for

Service limit value
new machine
5.9 (+5.9/0)
{0.6 (+0.6/0)}
N
FORWARD
Travel
Unit
Engine coolant temperature: Operating range

Engine speed: Low idle
Hydraulic oil temperature:
60 80C
Bucket
Lift arm
Travel
Bucket

60 80C
LOWER o
HOLD
LOWER o
FLOAT
LOWER o
FLOAT
N
{kg}
mm
20-100

SEN03933-00
Steering wheel
Category
Machine model
Item
Unit
Play
Engine stopped
Machine facing straight to front
mm
20 20
Max. 60
Operating effort
Flat, level, straight, dry, and paved road

Engine speed: Low idle (Bucket empty)
N {kg}
9.8 2.9
{1.0 0.3}
Max.14.7
{Max. 1.5}
Turns (Not including play)
Engine speed: High idle

Left lock right lock
Turns
3.7 0.4
3.7 0.8
3.7 0.4
Max. 4.8
3.7 0.3
3.7 1
24.5 37.8
{2.5 3.9}
45.5 58.8
{4.6 6.0}
45 2
17 2
294 30
{30 3.0}
Min. 238
{Min. 24.3}
50
30 (+2/0)
51
2,210 100
2,210 (+90/200)
2,150 100
2,150 (+150/200)
Low idle
Accelerator pedal
High idle
Operating effort
Beginning of
depression
Full open
Operating
angle
Neutral (1)
stroke ()
Brake pedal
Operating effort
Operating
angle
Neutral (1)
Max. (2)
Play
Engine started
Hydraulic oil temperature: Within operating range
Left lock right lock
Engine started
Measure at 150 mm from fulcrum of
pedal.
sec.
N {kg}
a For measuring posture, see Fig. A at end

of this section
Engine started
= 1 2
deg.
Operating angle: 20
N {kg}
a For measuring posture, see Fig. B at end

of this section
deg.
HST stall
Hydraulic stall
Engine coolant temperature: Within operating range

HST oil temperature: 60 80C
Hydraulic oil temperature: 45 55C
rpm
HST stall + hydraulic stall
2,030 (+130/200) 2,030 (+230/300)

1st
Power train (HST)
Standard value for

Service limit value
new machine
Operating time
Engine speed
WA320-6
Travel speed
(Bucket empty)
20-100
4 0.2
4 0.3
13 0.7
13 0.9
3rd
18.7 0.9
18.7 1.3
4th
38 1.9
38 (+1.9/2.7)
2nd
FORWARD
km/h

SEN03933-00
Category
Machine model
Item
WA320-6
Unit
1st
Power train (HST)
Low pressure
relief pressure
(Work equipment PPC circuit pressure)
Servo piston
control oil pressure
Servo piston
operating pressure
18.7 0.9
18.7 1.3
4th
38 1.9
38 (+1.9/2.7)
44.1 1.2
{450 12}
44.1 (+1.2/3.0)
{450 (+10/30)}
3.0 (+0.2/0)
{31 (+2/0)}
3.0 (+0.2/0.1)
{31 (+2/1)}
3.0 (+0.2/0)
{31 (+2/0)}
3.0 (+0.2/0.1)
{31 (+2/1)}
Max. 0.6
{Max. 6}
Max. 0.6
{Max. 6}

Gear speed selector switch: 1st
Travel speed control dial: 1 on Min.
side
Directional lever: Measure in both forward and reverse position.
Measure while driving at full throttle
(Max. speed: 5 km/h).
3.0 (+0.2/0)
{31 (+2/0)}
3.0 0.2
{31 2}

45 55C
Directional lever: FORWARD
Speed switch: 3rd or 4th speed
Travel at a speed of at least 10 km/h
3.0 (+0.2/0)
{31 (+2/0)}
3.0 (+0.2/0.1)
{31 (+2/1)}
20.6 (+1.0/0.5)
{210 (+10/5)}
20.6 2.0
{210 20}
Max. 14
Max. 14
mm
1 0.1
Max. 0.6
Holds position
Holds position
Engine speed: Full speed

45 55C
Directional lever: N
Steering
3rd
Wheel brake
13 0.9
Engine speed: Full speed

Directional lever: FORWARD
Speed switch: 2nd speed
Traction control switch: ON
Clutch control
pressure
Steering relief pressure
Performance
Engine speed:
Full speed
Hydraulic oil
temperature:
45 55C
Directional
lever: N
When brake pedal

releasing
When brake pedal

depressing

45 55C
Flat, horizontal, straight, dry paved road

surface
Speed when applying brake: 35 km/h
Braking delay: Within 0.1 sec.
Brake pedal operating effort:
322 N {33 kg}
Tire inflation pressure: Specified pressure
Measure braking distance
Thickness of lining
Disc wear
Parking brake
13 0.7
km/h
Transfer
4 0.3
REVERSE
High pressure
cut-off pressure
HST oil
pressure
4 0.2
2nd
Travel speed
(Bucket empty)
Standard value for

Service limit value
new machine
Performance

Flat paved road with 1/5 (1120') grade
Machine at operating condition
a For measuring posture, see Fig. C and
Fig. D at the end of this section
MPa
{kg/cm2}
20-100

SEN03933-00
Work equipment control valve Category
Machine model
Item
Lift arm
Speed
Bucket
Work equipment
Relief pressure

45 55C
Steering valve: Neutral
Apply no load
a For measuring posture, see
Fig. E Fig. H at the end of
this section
MPa
{kg/cm2}
RAISE
Standard value for

Service limit value
new machine
20.6 0.4
{210 4}
20.6 2.0
{210 20}
5.7 0.5
Max. 8.6
3.5 0.5
Max. 5.3
1.9 0.3
Max. 2.9
1.2 0.3
Max. 1.8
1.2 0.3
Max. 2
Max. 20
Max. 30
Max. 17
Max. 26
*1
LOWER
Sec.
TILT
*2
DUMP
TILT
*3
Bucket no load
Position of work equipment: Lift arm
and bucket in level position
Engine stopped
45 55C
Stop engine and leave for 5 minutes,
then measure for 15 minutes.
For measuring posture, see Fig. J at the
end of this section
mm
Max. fan speed

Engine coolant temperature: Min. 90C
Boost temperature: Min. 70C
HST oil temperature: Min. 95C
rpm
1,690 50
1,690 200
Fan drive pressure

Engine coolant temperature: Min. 90C
Boost temperature: Min. 70C
HST oil temperature: Min. 95C
MPa
{kg/cm2}
14.7 1.5
{150 15}
14.7 2.3
{150 23}
35
35
Lift arm cylinder
Bucket cylinder
Hydraulic drive fan
Unit

45 55C
Hydraulic drift
Proximity switch
WA320-6
Clearance between bucket positioner switch

Clearance between boom kick-out
switch

45 55C
mm
*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

SEN03933-00
Machine posture and procedure for performance measurement

a
Fig. A
Fig. D
Fig. B
Fig. E
Fig. C
Fig. F
20-100
SEN03933-00
a
Fig. G
Fig. H
Fig. J
20-100


SEN03933-00
20-100
SEN03933-00

2008 KOMATSU
All Rights Reserved
20-100
10
SEN03934-02
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
30

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
30-110
SEN03934-02
30-110

Tools for testing, adjusting, and troubleshooting
SEN03934-02

Testing and
adjusting item
Symbol
Measuring exhaust gas

color
Adjusting valve
clearance
Measuring compression
pressure
Measuring blow-by
pressure
Measuring engine oil

pressure
Measuring intake air

(boost) pressure
Commercially
Smoke meter
available
795-799-1131 Gear
Commercially
Clearance gauge
available
795-799-6700 Puller
For 107E-1 engine
795-502-1590 Gauge assembly
0 7 MPa {0 70 kg/cm2}
795-790-4410 Adapter
For 107E-1 engine
6754-11-3130 Gasket
For 107E-1 engine
799-201-1504 Blow-by checker
0 5 kPa {0 500 mmH2O}
799-101-5002 Hydraulic tester
Pressure gauge: 2.5, 6, 40, 60 MPa

{25, 60, 400, 600 kg/cm2}
790-301-1230 Nipple
799-101-5160 Nipple
799-401-2320 Gauge
799-201-2202 Boost gauge kit
101 200 kPa {760 1,500 mmHg}

{25, 60, 400, 600 kg/cm2}
790-261-1204 Digital hydraulic tester
Pressure gauge: 60 MPa {600 kg/cm2}
6732-81-3170 Adapter
10 1.0 mm o R1/8
6215-81-9710 O-ring
795-790-5110 Screw
799-201-2202 Boost gauge kit
795-790-4700 Tester kit
795-790-6700 Adapter
6754-71-5340 Connector
6754-71-5350 Washer
Commercially
Measuring cylinder
available
Commercially
Stopwatch
available
Commercially Hose
available
(Inside diameter: 14 mm)
79A-264-0021 Push-pull scale
0 300 N {0 30 kg}
0 300 N {0 30 kg}
Commercially
Scale
available
799-101-5002 Analog hydraulic tester

{25, 60, 400, 600 kg/cm2}
3
Measuring fuel return
rate and leakage
Testing accelerator
pedal
Testing directional lever K
Testing and adjusting

HST oil pressure
Remarks
Q'ty
799-201-9001 Handy smoke checker
Measuring fuel
compression pressure
Part Name
Part No.
Bosch index: Level 0 9
30-110

SEN03934-02
Testing and
adjusting item
Symbol
Q'ty
Remarks

{25, 60, 400, 600 kg/cm2}
799-401-3200 Adapter
02896-11009 O-ring
0 300 N {0 30 kg}

{25, 60, 400, 600 kg/cm2}
799-205-2200 Tachometer kit
Digital display: 6 99999.9 rpm

{25, 60, 400, 600 kg/cm2}
799-401-3400 Adapter
02896-11015 O-ring

{25, 60, 400, 600 kg/cm2}
793-605-1001 Brake test kit
1
Testing clutch control
pressure
M
2
Testing steering wheel

steering oil pressure
P
1
Testing hydraulic fan
3
accumulator charge
pressure
Testing wheel brake oil

pressure
Part No.
Part Name
790-101-1430 Coupler
790-101-1102 Pump
790-301-1720 Adapter
799-101-5160 Nipple
799-401-2220 Hose
790-261-1130 Coupling
For hose size #03
For hose size #05
20 1.5 mm o R1/8
Length: 5 m
Holding work equipment position
793-463-1100 Stopper

parking brake control
cable
0 300 N {0 30 kg}
0 300 N {0 30 kg}
Commercially
Scale
available

{25, 60, 400, 600 kg/cm2}

{25, 60, 400, 600 kg/cm2}
Testing work equipment lever

work equipment oil
pressure

work equipment PPC
oil pressure
30-110

Testing and
adjusting item
Diagnosis for engine

related controller, sensor actuator and harness
Diagnosis for chassis

Symbol
Part No.
SEN03934-02
Part Name
Q'ty
Remarks
799-601-7400 T-adapter assembly
AMP040 Connector
AMP070 Connector
DT, HD30 Connector
DRC26-40 (5 pins)
799-601-7360 Adapter
REL-5P (5 pins)
799-601-7310 T-adapter
SWP (12 poles)
799-601-7070 T-adapter
SWP (16 poles)
Connected with engine
795-799-5530 T-adapter
Engine coolant temperature
799-601-4230 T-adapter
Boost temperature/pressure sensor
799-601-4130 T-adapter
Ne sensor, CAM sensor
799-601-4160 T-adapter
Hydraulic pressure sensor
799-601-4211 T-adapter
Controller (50 poles)
799-601-4220 T-adapter
799-601-4140 T-adapter
Atmospheric pressure sensor
799-601-4340 T-adapter
Pump actuator
799-601-4260 T-adapter
799-601-4190 T-adapter
Common rail pressure sensor
799-601-2500
or
799-601-2700
or
799-601-2800
or
T-adapter
799-601-2900
or
799-601-7100
or
799-601-8000
799-601-2900 is not supplied
799-601-2600 T-adapter box
Econo (Excl. 799-601-2700)
799-601-2740 Adapter for MIC
For MIC-5P
799-601-4211 Adapter for DRC
For DRC50
799-601-9020 Adapter for DT
For DT2P
For DT3P
799-601-7000
or
799-601-7100
or
T-adapter assembly
799-601-7400
or
799-601-8000
799-601-7010 Adapter for X
For X1P
For X2P
For X3P
For X4P
799-601-7050 Adapter for SWP
For SWP6P
For SWP8P (Excl. 799-601-8000)
30-110

SEN03934-02
Testing and
adjusting item
Diagnosis for chassis

Symbol
Part No.
Part Name
Q'ty
799-601-7080 Adapter for M
For M1P (Excl. 799-601-7000 and

799-601-7100)
For M2P
For M3P
For M4P
For M6P
799-601-7150 Adapter for S
For S10P
799-601-7180 Adapter for AMP040
For A8P (799-601-7400 only)
For A12P (Excl. 799-601-7000 and

799-601-7100)
For S16PW (799-601-8000 only)
For SW16P
For M8P
799-601-7360 Adapter for relay
For REL-5P
For REL-6P
799-601-7520 Adapter for 070
For 070-12P
799-601-7530 Adapter for 070
For 070-14P
799-601-7540 Adapter for 070
For 070-18P
799-601-7550 Adapter for 070
For 070-20P
799-601-9000
T-adapter assembly
or
799-601-9200
For DT2P (Incl. in 799-601-4101

and 799-601-4201)
For DT3P
For DT4P (Incl. in 799-601-4101

and 799-601-4201)
For DT6P
799-601-9060 Adapter for DT (Gray)
For DT8PGR
799-601-9070 Adapter for DT (Black)
For DT8PB
799-601-9080 Adapter for DT (Green)
For DT8PG
For DT12PGR
For DT12PB
For DT12PG
799-601-9140 Adapter for DT (Brown)
For DT12P
For DRC-40
For DRC-24
Multi-adapter for
DT24, DTM2
For DT24, DTM2
799-601-9890
Measuring coolant and
oil temperature
799-101-1502 Digital thermometer
Measuring time and

speed
Commercially
Stopwatch
available
Measuring voltage and

resistance
Commercially
Tester
available
30-110
Remarks

Testing and
adjusting item
Symbol
Removal and installation

of boost pressure and
temperature sensor
Part No.
SEN03934-02
Part Name
Commercially
TORX wrench
available
795T-981-1010 Socket
Commercially
Socket
available
Removal and installation

of engine coolant
temperature sensor
Q'ty
Remarks
3.26 mm TORX wrench

(KTC Q4T15 or equivalent)
19 mm deep socket
(MITOLOY 4ML-19 or equivalent)
(Appleid engine serial number:
26530193)
21mm deep socket

(MITOLOY 4ML-21 or equivalent)
(Appleid engine serial number:
2650000626530192)
Sketches of special tools

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketched.
Socket
30-110

Measuring engine speed
SEN03934-02

k
k
Put chocks under the tires securely.

When measuring, check that there are no
persons around the machine.
Measure the engine speed under the following

condition.
q
Engine coolant temperature:
Within operating range
q
q
HST oil temperature:
1.
Measuring engine speed (low idle and high

idle)
1) Referring to Special function of machine
monitor, select the real time monitoring
function of the service mode.
2) Display ENG SPEED from the monitoring items of the machine monitor.
a Monitoring item
Code No. 01001: ENG SPEED
(Engine speed)
3)
30-110
2.
Measuring HST stall speed

2) Select the two-item simultaneous monitoring (2 ITEMS) and then enter the following
code numbers directly.
a Monitoring items
[1] Code No.01001: ENG SPEED
(Engine speed)
[2] Code No.04408: HST OIL TEMP
(HST oil temperature)
3)
4)
Start the engine.

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).
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.
Start the engine, set it in the measuring

condition, and measure the engine speed.

3.
Measuring hydraulic stall speed

2) Display ENG SPEED from the monitoring items of the machine monitor.
a Monitoring item
Code No. 01001: ENG SPEED
(Engine speed)
3)
4)
Run the engine at high idle.

Relieve the lift arm cylinder or bucket cylinder on the extraction side and measure
the engine speed.
a Finish measurement in a short time
so that the hydraulic oil temperature
will not exceed 120C.
SEN03934-02
4.
Measuring HST stall and hydraulic stall (full

stall) speed
1) Set the machine monitor as in 2. Measuring HST stall speed.
2) Start the engine.
3) Lower the bucket to near the ground, then
(portion a).
4)
While running the engine at high idle, stall

the HST and relieve the lift arm cylinder or
bucket cylinder on the extraction side
simultaneously and measure the engine
speed at this time.
120C.
30-110

Measuring exhaust gas color
SEN03934-02

a
Necessary tools
Symbol
A
k
1.
Part No.
Part Name
799-201-9001
Handy smoke checker
Commercially
available
Smoke meter
When installing and removing the measuring

instruments, take care not to touch a hot part.
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.
Measure the exhaust gas color under the following condition.
q
Measuring with handy smoke checker A1
1) Stick a sheet of filter paper to smoke
checker A1.
2) Insert the exhaust gas intake pipe in the
muffler (exhaust pipe).
3) Start the engine and heighten the engine
coolant temperature to the operating range.
4) Accelerate the engine suddenly and run it
at HST stalling and hydraulic stalling, and
operate the handle of smoke checker A1
so that the filter paper will absorb the
exhaust gas.
2.
Measuring with smoke meter A2

1) Insert the probe of smoke meter A2 in the
outlet of the muffler (exhaust pipe) and fix
it to the exhaust pipe with a clip.
2)
3)
4)
5)
5)
6)
30-110
Connect the probe hose, receptacle of the

accelerator switch, and air hose to smoke
meter A2.
a Keep the pressure of the supplied
compressed air at 1.5 MPa {15 kg/
cm2} or below.
Connect the power cable to a 100 V AC
receptacle.
a Confirm that the smoke meter power
switch is in the OFF position, before connecting the power cable to an outlet.
Loosen the cap nut of the suction pump
and fit the filter paper.
a Fit the filter paper securely so that the
exhaust gas will not leak.
Turn on the power switch of smoke meter A2.
Take out the filter paper and compare it

with the attached scale for judgement.
Remove the measurement tool after the
measurement, and make sure that the
machine is back to normal condition.
10

6)
7)
8)
9)
SEN03934-02
Start the engine and keep it running until

the engine coolant temperature rises to
the operating range.
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.
Put the polluted filter paper on non-polluted filter paper (more than 10 sheets) in
the filter paper holder, and read the indicated value.
After finishing work, remove the used
instruments and return the removed parts.
30-110
11

Adjusting valve clearance
SEN03934-02

a
Part No.
Rotate the crankshaft forward (clockwise, seeing from the fan) with gear B1 and set wide slit
(b) of the rotation sensor ring to projection top
(a) of front cover.
a Projection top (a) must be within the range
of wide slit (b) when it is seen from the air
conditioner compressor side.
a If you can see the yellow marks (c) of projection top (a) and the damper periphery,
you may set them to each other.
a After the above positioning, the No. 1 cylinder or No. 6 cylinder is not at the top
dead center (TDC). Take care. (The cylinder is at 76 88 before the top dead center.)
4.
Check the movement of the rocker arm of the

No. 1 cylinder to judge the valve to be
adjusted.
Part Name
795-799-1131
Gear
Commercially
available
Clearance gauge
Adjust the valve clearance under the following

condition.
q
Engine coolant temperature: Normal temperature
1.
Remove cylinder head cover (1). For details,

see Disassembly and assembly, Removal and
installation of cylinder head assembly.
a Removal of the engine hood is unnecessary.
2.
3.
Necessary tools
Symbol
B
Remove plate (2) and plug (3) at the bottom of

the starting motor and insert gear B1.
30-110
12
If you can move the rocker arms of air

intake valves (IN) with the hand by the
valve clearance, adjust the valves marked
with Q in the valve arrangement drawing.
If you can move the rocker arms of
exhaust valves (EX) with the hand by the
valve clearance, adjust the valves marked
with q in the valve arrangement drawing.
Valve arrangement drawing

5.
Adjust the valve clearance according to the following procedure.

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 adjustment 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
arrangement drawing were adjusted in
steps 4 and 5, adjust the valves marked
with Q.
a If the valves marked with Q in the valve
arrangement 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 nut:
24 4 Nm {2.45 0.41 kgm}
SEN03934-02
30-110
13

Measuring compression pressure
SEN03934-02
Measuring compression pressure1

a
Part No.
Part Name
795-799-6700
Puller
795-502-1590
Gauge assembly
795-790-4410
Adapter
6754-11-3130
Gasket
When measuring the compression pressure, take care not to burn yourself on the
exhaust manifold or muffler or get caught
in a rotating part.
Measure the compression pressure after the
engine is warmed up.
(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.
3.
Loosen injector terminal nut (4) and remove

the terminal from the injector.
5.
Set the cylinder to be checked to the compression top dead center.

a How to turn the crankshaft, refer to
Adjusting valve clearance.
a When the cylinder is at the compression
top dead center, the rocker arm of the cylinder can be moved by the valve clearance with the hand.
6.
Remove rocker arm assembly (5).
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
impacts of a slide hammer.
a Do not remove the injector by prying its
top up.
Necessary tools
Symbol
4.
Disconnect fuel high-pressure tube (3).
30-110
14

SEN03934-02
16. Rotate the engine with the starting motor and
measure the compression pressure.
a Read the gauge when its pointer is stabilized.
10. Fit gasket C4 to the end of adapter C3 and

insert them in the injector mounting portion.
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 inlet connector insertion side.
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:
36 5 Nm {3.67 0.51 kgm}
2)
3)
14. Adjust the valve clearance.

a See Adjusting valve clearance.
4)
5)
Tighten injector holder mounting bolts (10)

by 3 4 turns.
Set fuel inlet connector (7).
a Push in the fuel inlet connector until
the O-ring is fitted and the connector
clicks.
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}
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-injection
cranking mode.
k If the engine is not set in the no-injection cranking mode, it starts during
measurement and that is dangerous.
Accordingly, be sure to set the engine
in the no-injection cranking mode.
30-110
15
SEN03934-02
6)
Permanently 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 highpressure 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.

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}
Tighten the injector terminal nut to the following torque.

3 Terminal nut:
1.5 0.25 Nm {0.15 0.025 kgm}
Tighten the head cover to the following torque.

Head cover mounting nut:
24 4 Nm {2.45 0.41 kgm}
30-110
16

Measuring blow-by pressure
SEN03934-02
Measuring blow-by pressure

a
5.
While pressing the brake pedal, set the directional lever or switch to the F (forward) or R
(reverse) position.
k Keep pressing the brake pedal securely.
6.
Press the accelerator pedal gradually to the

high idle. While running the engine at HST
stalling and hydraulic stalling, measure the
blow-by pressure.
than 20 seconds. Take care that the HST
oil temperature will not exceed 120C.
a Normally, the blow-by pressure should be
measured while the engine is operated at
the rated output. In the field, however, an
approximate value can be obtained by
HST stalling and hydraulic stalling.
a If it is impossible to run the engine at the
rated output or HST stalling and hydraulic
stalling, 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 rated 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, deterioration of oil, high deterioration speed of oil, etc. which are related
to the abnormal blow-by pressure.
7.
Remove the measurement tool after the measurement, and make sure that the machine is
back to normal condition.
Necessary tools
Symbol
Part No.
799-201-1504
Part Name
Blow-by checker
Measure the blow-by pressure under the following condition.

q
q
q
1.
Stop the engine. Install nozzle [1] and hose [2]

of blow-by checker D to blow-by hose (1) and
connect them to gauge [3].
Blow-by hose (1) comes out from the rear

left of the engine and its end is fixed to the
machine lower frame.
2.
Start the engine and increase the engine coolant temperature to the operating range.
3.
Press the left brake pedal securely.
4.
Release the parking brake.
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17

Measuring engine oil pressure
SEN03934-02
Measuring engine oil pressure

a
Part No.
Part Name
799-101-5002
Hydraulic tester
799-301-1230
Nipple
799-101-5160
Nipple
799-401-2320
Gauge
Measure the engine oil pressure under the following condition.

q
1.
Open the engine left side cover.
2.
Remove plug (1) from oil filter head.
3.
4.
Start the engine and heighten the coolant temperature to the operating range.
5.
While running the engine at low idle and high

idle, measure the oil pressure.
6.
Remove the measurement tool after the measurement, and make sure that the machine is
back to normal condition.
Necessary tools
Symbol
Install nipples E2 and E3, then connect

hydraulic tester E4 (1 MPa {10 kg/cm2}).
30-110
18

Measuring intake air (boost) pressure
Measuring intake air (boost)

pressure
a
k
k
1.
2.
1
Necessary tools
Symbol
F
SEN03934-02
Part No.
Measurement with measuring tool

1) Open the engine right side cover.
2) Remove air boost pressure pickup plug (1)
(R1/8).
Part Name
799-101-5002
Hydraulic tester
799-201-2202
Boost gauge kit
When installing and removing the measuring instruments, take care not to touch a
hot part of the engine.
Measure the intake air pressure (boost pressure) under the following condition.
q
q
q
3)
Install elbow [1] in hydraulic tester F1 and

nipple [2] in boost gauge kit F2 and connect pressure gauge [3].
4)
Start the engine and increase the coolant

temperature to the operating range.
Run the engine at medium or higher
speed to drain the oil from the hose.
a Insert 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.
a If the oil is left in the hose, the gauge
does not work. Accordingly, be sure
to drain the oil.
Press the left brake pedal securely.
Release the parking brake.
While pressing the brake pedal, set the
directional lever to the F (forward) or R
(reverse) position.
k Keep pressing the brake pedal
securely.
Measurement with monitoring function

1) Referring to Special functions of machine
monitor (EMMS), select the real-time
monitoring function in the service mode.
2) Display CHG PRESS-A in the monitoring
functions of the machine monitor.
a Monitoring item
Code No. 36500: CHG PRESS-A (Boost
pressure)
5)
3)
Press the accelerator pedal gradually to

the high idle and measure the boost pressure when HST stalling and hydraulic
stalling.
Do not keep the HST stalled for more that
20 seconds so that the HST oil temperature will not exceed 120C.
6)
7)
8)
30-110
19
SEN03934-02
9)

Measuring intake air (boost) pressure
Press the accelerator pedal gradually to

the high idle. While running the engine at
high idle, stall the HST and hydraulic work
equipment and measure the intake air
pressure (boost pressure).
120C.
10) Remove the measurement tool after the

measurement, and make sure that the
machine is back to normal condition.
30-110
20

Handling fuel system equipment
Handling fuel system equipment

a
SEN03934-02
Precautions for testing and maintaining fuel

system
The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign matter enters this system, it can cause a
trouble.
When testing and maintaining the fuel system,
take care more than the past. If dust, etc. sticks
to any part, wash that part thoroughly with
clean fuel.
Precautions for replacement of fuel filter cartridge
The fuel filter cartridge used must be a genuine
Komatsu part.
The fuel injection pump and nozzle of the common rail type fuel injection system (CRI) consist of more precision parts than those used for
the current pumps and nozzles. This system,
therefore, employs a special filter with highly
efficient filtering performance to prevent mixing
of foreign substances. Thus, substituting it with
a non-genuine filter could cause troubles in the
fuel system. It is strictly prohibited to use such
part.
Releasing residual pressure in

fuel system
a
Pressure is generated in the low-pressure circuit and high-pressure circuit of the fuel system while the engine is running.
Low-pressure circuit:
Feed pump Fuel filter Supply pump
High-pressure circuit:
Supply pump Common rail Injector
The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level
automatically 30 seconds after the engine is
stopped.
Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit must be released completely. Accordingly,
observe the following.
Before testing the fuel system or removing
its parts, wait at least 30 seconds after stopping the engine until the residual pressure
in the fuel circuit is released. (Do not start
the work just after stopping the engine
since there is residual pressure.)
30-110
21

Measuring fuel pressure
SEN03934-02

a
k
k
1.
2)
Install adapter G2 and nipple [1] of

hydraulic tester G1 and connect them to
oil pressure gauge [2].
a Use the oil pressure gauge of 2.5
MPa {25 kg/cm2}.
3)
Run the engine at low idle and measure the

pressure in the fuel low-pressure circuit.
a If the pressure in the fuel low-pressure circuit is in the following range, it
is normal.
Necessary tools
Symbol
Part No.
Part name
799-101-5002
Hydraulic tester
790-261-1204
Digital hydraulic tester
6732-81-3170
Adapter
(10 1.0 mm o PT1/8)
6215-81-9710
O-ring
799-401-2320
Hydraulic tester
795-790-5110
Screw
799-201-2202
Boost gauge kit

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.
Since the pressure in the high-pressure circuit from the supply pump through the
common rail to the fuel injector is very
high, it cannot be measured.
Measuring pressure in fuel low-pressure
circuit
1) Remove fuel pressure pickup plug (1)
from the fuel main filter.
4)
30-110
22
During cranking
0.3 1.1 MPa

{3.1 11.3 kg/cm2}
At low idle
0.5 1.3 MPa

{5.1 13.3 kg/cm2}
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.
After finishing measurement, remove the

measuring tools and return the removed
parts.
3 Fuel pressure pickup plug:
10 2 Nm {1 0.2 kgm}

2.
SEN03934-02
Measuring pressure in fuel return circuit

1) Remove fuel pressure pickup plug (2)
from the fuel return block.
2)
Install nipple [3] of hydraulic tester G1 and

nipple [1] and connect them to hydraulic
tester G3.
a Nipple [3]:
790-301-1181, 07002-11223
3.
Measuring fuel negative-pressure circuit

pressure
1) Remove joint bolt (2) of fuel hose (1)
between the prefilter and supply pump.
2)
a
3)
3)
Run the engine at low idle and measure

the 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
At low idle
Max. 0.02 MPa

{Max. 0.19 kg/cm2}
4)
4)
Connect fuel hose (1) to supply pump (3)

by tool G4 instead of joint bolt (2).
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}
Connect tool G5 to tool G4.

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.
parts.
3 Fuel pressure pickup plug:
24 4 Nm {2.4 0.4 kgm}
5)
6)
Run the engine at high idle and measure

the circuit negative pressure.
Circuit standard negative pressure:
Max. 50.7 kPa {380 mmHg}
If the negative pressure is higher than the
standard pressure, the fuel prefilter may
be clogged. In this case, replace the fuel
prefilter and measure again.
measuring instruments and return the
removed parts.
3 Joint bolt (2):
19.6 29.4 Nm {2.0 3.0 kgm}
30-110
23

Measuring fuel return rate and leakage
SEN03934-02
Measuring fuel return rate and

leakage
a
Necessary tools
Symbol
k
k
1.
Part No.
795-790-4700 Tester kit
795-790-6700 Adapter
3
H
Part name
6754-71-5340 Connector
6754-71-5350 Washer
Commercially
Measuring cylinder
available
Commercially
Stopwatch
available
Commercially
Hose (Inside diameter 14 mm)
available
4)
Prepare receiving pan of about 20 liters to

receive the fuel flowing out during measurement.
Measuring supply pump delivery
2) Loosen clamp (1) of supply pump discharge tube (2) and disconnect the tube.
3)
30-110
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 receiving pan.
24
5)
Crank the engine for 30 seconds and

measure the delivery with measuring cylinder H4.
a Adjust the route of the test hose so
that it will not slacken and put its end
in receiving pan.
a Do not crank the engine for more than
30 seconds to protect the starting
motor in any case other than this
measurement.
a If the supply pump delivery is in the
following standard range, it is normal.
At cranking speed
(125 rpm)
Min. 75 cc
At cranking speed
(150 rpm)
Min. 90 cc

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}

2.
Measuring return rate from supply pump

2) Disconnect return hose (1) from the supply pump.
a The return hose is connected by a
quick coupler.
SEN03934-02
5)

the return rate in 25 seconds with measuring cylinder H4.
a If the return rate from the supply
pump is in the following range, it is
normal.
At low idle
k
3)
4)
Max. 400 cc

may measure the return rate while
rotating the engine with the starting motor. Do not rotate for more
than 25 seconds continuously,
however, for protection of the starting motor.
Install connector H3 and cap nut [1] of tester kit H1 to the return hose to stop the fuel
from flowing out.
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.
6)

parts.
a When measuring the leakage from
the pressure limiter or finishing the
measurement: Return the removed
parts to their original positions.
a When measuring the leakage from
the injector: Leave the removed parts
as they are and keep the test hose
end in the receiving pan.
30-110
25

SEN03934-02
3.
Measuring leakage from pressure limiter

2) Remove the main fuel filter bracket mounting bolt (2), and move the fuel filter and
bracket assembly (3).
6)

the leakage in 1 minute with measuring
cylinder H4.
a If the leakage from the pressure limiter
is in the following range, it is normal.
At low idle
3)
Disconnect return hose (4) from the pressure limiter.

a Install the seal washer to the connector bolt.
7)
4.
4)
5)
30-110
Install removed connector bolt (5) and cap

nut [1] of tester kit H1 to the return hose to
stop the fuel from flowing out.
Install connector H3 to the common rail
and connect test hose [2] of tester kit H1.
26
0 cc
(No leakage)

measuring tools and return the removed parts.
3 Joint bolt:
24 4 Nm {2.4 0.4 kgm}
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
measurement.
k The fuel returning from the supply
pump flows out during measurement of the return rate from the
injector. Accordingly, keep the test
hose end in the receiving pan.
2) Remove connector bolt (6) of the return
block.

SEN03934-02
3)
Install connector bolt [3] of adapter H2

instead of the removed connector bolt and
connect test hose [4].
4)

the 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.
5)
During cranking
Max. 90 cc
At low idle
Max. 180 cc

may measure the return rate while
rotating the engine with the starting motor. Do not rotate for more
than 20 seconds continuously,
however, for protection of the starting motor.

parts.
3 Joint bolt:
24 4 Nm {2.4 0.4 kgm}
30-110
27

Bleeding air from fuel circuit
SEN03934-02
Bleeding air from fuel circuit

a
k
If fuel is used up or if a fuel circuit part is

removed and installed, bleed air from the fuel
circuit according to the following procedure.
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

Checking leakage in fuel system
Checking leakage in fuel system

k
SEN03934-02
Very high pressure is generated in the highpressure circuit of the fuel system. If fuel
leaks while the engine is running, it is dangerous since it can catch fire.
After testing the fuel system or removing
its parts, check it for fuel leakage according
to the following procedure.
Clean and degrease the engine and the parts
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 a speed below 1,000 rpm

and stop it after its speed is stabilized.
3.
Inspect the fuel piping and devices for fuel

leakage.
a Check mainly around the high-pressure
circuit parts coated with the color checker
for fuel leakage.
a If fuel leakage is recognized, repeat the
procedure from step 1 after repairing the
leakage.
4.
Run the engine at low idle.
5.

leakage.
for fuel leakage.
leakage.
6.
Run the engine at high idle.
7.

leakage.
for fuel leakage.
leakage.
8.
Start the engine and stall the HST or relieve

the hydraulic pump to apply some load on the
engine.
9.

leakage.
for fuel leakage.
leakage.
a If no fuel leakage is detected, check is
completed.
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29

Handling cylinder cut-out mode operation
SEN03934-02
Handling cylinder cut-out mode

operation
a
1.
Cylinder cut-out mode operation means to run

the engine with the fuel injectors of 1 or more
cylinders disabled electrically to reduce the
number of effective cylinders. The purposes
and effects of this operation are as follows.
This operation is used to find out a cylinder
which does not output power normally (or,
combustion in it is abnormal).
2.
When a cylinder is selected for the cylinder

cut-out mode operation, if the engine speed
and 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 electronically, 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
monitor.
For details, see Special functions of
machine monitor (EMMS), Cylinder cutout mode operation function.
30-110
30
Handling no-injection cranking

operation
a
No-injection cranking means to crank the

engine with the starting motor while all the
injections are stopped electrically. The purpose
and effect of this operation are as follows.
When a machine or engine has been stored for
a long time, implementing the no-injection
cranking before starting the engine lubricates
the engine parts and thus prevents its seizure.
The no-injection cranking operation is set from
the service mode of the machine monitor. For
details, see Special functions of machine
monitor (EMMS), No-injection cranking function.

Handling controller voltage circuit
Handling controller voltage circuit

1.
2.
When disconnecting or connecting a connector

between the engine controller and engine, be
sure to turn the starting switch OFF.
If a T-adapter is inserted in or connected to a
connector between the engine controller and
engine for troubleshooting, do not start the
engine.
a You may turn the starting switch to the
OFF or ON position but must not turn it to
the START position.
SEN03934-02
Check of muffler and muffler

stack for looseness and damage
1.
Check the muffler and muffler stack visually for

a crack and damage. If any part is damaged,
replace it.
2.
Check the mounting bolts and nuts of the muffler and muffler stack for looseness. If they are
loosened, retighten them.
30-110
31

Check of muffler function
SEN03934-02
Check of muffler function

q
Check the muffler for abnormal sound and difference in sound from a new machine. If it
makes abnormal sound, repair it, referring to
the Troubleshooting Volume.
30-110
32
Check of installed condition of

cylinder head and manifolds
Check the installed condition of the cylinder head

and air intake manifold and exhaust manifold. If
they are loosened, retighten them.
a For the tightening torque, see the "Disassembly and assembly" volume.

Check of engine piping for damage and looseness
Check of engine piping for

damage and looseness
SEN03934-02
Air intake and exhaust systems:

Check the piping for damage, looseness of the
mounting bolts and nuts, and suction of air and
leakage of exhaust gas through the joints. If it
is loosened or damaged, retighten or repair.
Cooling system:
mounting bolts and nuts, and leakage of water
through the joints. If it is loosened or damaged, retighten or repair.
Testing and adjusting air conditioner compressor belt tension
Testing
q
Press the middle point between air conditioner
compressor pulley and drive pulley with a finger
and measure deflection (a) of the belt.
a Pressing force: Approx. 98 N {Approx. 10 kg}
a Standard deflection (a): 11 14.5 mm
Fuel system:
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
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).
30-110
33

Replacing alternator belt
SEN03934-02

a
a
k
The auto-tensioner is provided for the alternator belt. Thus, testing and adjustment of the
belt is usually no necessary.
Remove air conditioner compressor belt before
replacing the alternator belt.
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).

Check each pulley for breakage and crack.
30-110
34

SEN03934-02
30-110
35
SEN03934-02

2009 KOMATSU
All Rights Reserved
30-110
36
SEN03935-02
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
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
30-120
SEN03935-02
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

Checking operating force of accelerator pedal
Checking operating force of

accelerator pedal
SEN03935-02
a
After greasing, wipe off grease completely (No

grease is adhered on roller surface and roller
sliding surface).
5.
After finishing the work, remove the measuring

Necessary tools
Symbol
Part No.
Part Name
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 contact with a point 150 mm from the pedal
fulcrum.
Testing accelerator pedal operating angle

1.
2.
3.
2.
3.
4.
Start the engine.

Measure operating angle () when the pedal is
operated from the low idle position to the high
idle position.
Apply angle gauge [1] to accelerator pedal (1)
and measure pressing angle between low idle
angle 1 and high idle angle 2 ( = 1 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).
Stop the engine.
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)
30-120

Checking directional lever
SEN03935-02
Checking directional lever
Necessary tools
Symbol
Part No.
Part Name
79A-264-0021
Push-pull scale
Commercially
available
Scale
K
k

Checking operating effort of directional lever

1.
2.
Stop the engine.

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.
2.
Stop the engine.

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

Testing and adjusting HST oil pressure
Testing and adjusting HST oil

pressure
SEN03935-02
Necessary tools
Symbol
Part No.
Part Name
799-101-5002
Analog type hydraulic tester
790-261-1204
Digital type hydraulic tester
L
k
a
a
Loosen the oil filler cap slowly to release

the pressure inside the hydraulic tank.
HST oil temperature when measuring: Within
operating range
The high-pressure relief pressure is the same
as the safety pressure of the main circuit, so it
cannot be measured. (Normally, the cut-off
valve is actuated first, so it does not rise to the
safety valve set pressure)
Testing
Testing high-pressure cut-off oil pressure
[Testing with monitoring function]
1. Referring to Special functions of machine
monitor (EMMS), select the real-time monitoring 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)
a Install the oil pressure gauge L to nipple (1) of the forward circuit.
3.
Measure the high-pressure cut-off oil pressure

under the following conditions.
1) Lower the bucket to near the ground, then
(portion a).
a Set the directional lever to FORWARD and the speed selector switch
to 2nd and traction control switch to
ON.
2)
3)
4)
Run the engine at full throttle and press

the bucket into part a until the machine
does not move forward.
k Carry out the measurement on
hard ground where it is difficult for
the tires to slip.
Keep the engine running at full throttle,
check that the tires are not turning, then
measure the oil pressure.
After finishing the work, remove the measuring instruments and return the
removed parts.
30-120

SEN03935-02
Testing low-pressure relief pressure (basic
pressure of work equipment PPC circuit)
[Testing with monitoring function]
See Testing high-pressure cut-off oil pressure.
[Testing with tools]
1. Remove low-pressure relief pressure measurement 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.
3.
4.
2.
Remove servo piston control pressure measurement plug (5) (DA pressure) (10 mm, P =
1.25 mm).
3.
Install nipple L [3], then connect oil pressure

gauge L [1], L [2] (6 MPa {60 kg/cm2}).
4.
Place the directional lever at N, run the engine

at high idle, and measure the control pressure
when the brake pedal is depressed and when it
is released.
a The brake pedal is connected to the inching valve and controls the control pressure.
Install a nipple, then connect oil pressure

gauge L (6 MPa {60 kg/cm2}).
Place the directional lever at N, run the engine

at high idle, and measure the low-pressure
relief pressure.
Testing servo piston control pressure (DA pressure)

1. Remove floor frame cover (4) (bottom left of
operator's cab).
5.
30-120

Testing servo piston actuating pressure

1. Remove servo piston actuation pressure measurement plug (6) or (7) (G 1/4) (width across
flats for hexagonal head wrench: 8 mm).
q
Plug (6): For FORWARD circuit (port: X1)
q
Plug (7): For REVERSE circuit (port: X2)
2.
Install a nipple L [3], then connect oil pressure

gauge L [1], L [2] (6 MPa {60 kg/cm2}).
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 lowest speed side.
2) Measure the oil pressure while driving forward at full throttle (5 km/h). Similarly,
measure while driving in reverse.
a Do not press the brake pedal.
4.
SEN03935-02
Adjusting
a
The high-pressure relief pressure is also the

safety pressure of the main circuit, so it cannot
be measured. (Normally, the cut-off valve is
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 correct, 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 follows.
q
To INCREASE pressure, turn
CLOCKWISE.
q
To DECREASE pressure, turn
COUNTERCLOCKWISE.
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}
After completion of adjustment, repeat the

measurement procedure to check the
high-pressure cut-off oil pressure again.
30-120

SEN03935-02
Adjusting low-pressure relief valve
a If the low-pressure relief pressure is not correct, adjust the low-pressure relief valve as follows.
2. Remove cap (12) and loosen low-pressure
relief valve (11) and locknut (13) and rotate
adjustment screw (14) to adjust the pressure.
q
CLOCKWISE.
q
COUNTERCLOCKWISE
adjustment screw: 0.38 MPa {3.9 kg/cm2}
Adjusting DA valve
a If the servo piston control pressure is not correct, adjust the DA valve as follows.
2. Loosen locknut (16) of DA valve (15), then turn
adjustment screw (17) to adjust.
q
CLOCKWISE.
q
COUNTERCLOCKWISE
a
a
30-120

measurement procedure to check the lowpressure relief pressure again.

measurement procedure to check the control pressure again.

Testing clutch control pressure
SEN03935-02
Testing clutch control pressure
3.
Connect hydraulic tester M1 (6 MPa {60 kg/cm2})

and adapter M2 (Hose size: For # 03).
4.
Set the speed selector switch to 3rd or 4th,

travel at a speed of at least 10 km/h, and measure the clutch inlet pressure (clutch solenoid
valve output pressure).
5.

Necessary tools
Symbol
Part No.
Part Name
799-101-5002
790-261-1204
799-401-3200
Adapter
02896-11009
O-ring
1
M
2
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).
2.
Disconnect clutch solenoid valve output pressure (clutch inlet pressure) hose (2).
30-120

Testing and adjusting steering wheel
SEN03935-02
Testing and adjusting steering

wheel
Measuring operating effort of steering wheel

1
Necessary tools
Symbol
Part No.
79A-264-0021
q
Road surface:
Flat, horizontal, dry paved surface
q
Within green range on engine coolant
temperature gauge
q
45 55C
q
Tire inflation pressure:
Specified pressure
q
Engine speed:
Low idle (bucket empty)
1.
Install push-pull scale N to the steering wheel

knob (2).
2.
Start the engine.

a After starting the engine, raise the bucket
approx. 400 mm and remove the frame
lock bar.
3.
Pull push-pull scale N in the tangential direction and measure the value when the steering
wheel moves smoothly.
a Do not use the value when the steering
wheel starts to move.
4.

Part Name
Push-pull scale
Measuring play of steering wheel

a
q
Engine speed: Stopped
q
Machine posture: Facing straight forward
1.
Move the steering wheel (1) 2 or 3 times lightly

to the left and right, check that the steering
mechanism is at the neutral position, then
make mark (A) on the outside frame of the
machine monitor.
Turn the steering wheel to the right, and make
mark (B) at the position where the operating
effort starts to become heavy.
2.
3.
Turn the steering wheel to the left in the opposite direction from Step 2, and make mark (C)
a t t h e p o i nt 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

Testing and adjusting steering wheel
SEN03935-02
Measuring operating time for steering wheel

a
q
Road surface:
q
Within green range on engine coolant
temperature gauge
q
45 55C
q
Specified pressure
q
Engine speed
Low idle and high idle
1.
Start the engine.

a After starting the engine, raise the bucket
approx. 400 mm and remove the frame
lock bar.
Operate the steering wheel to the end of its
stroke to turn the machine to the left or right.
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.
2.
3.
30-120
11

Testing and adjusting steering oil pressure
SEN03935-02
Testing and adjusting steering oil

pressure
1
3.
Fit a nipple P [3] to the steering circuit pressure

measurement plug hole, then install oil pressure
gauge P [1] and P [2] (40 MPa {400 kg/cm2}).
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.
Necessary tools
Symbol
Part No.
Part Name
799-101-5002
790-261-1204
Measuring condition
q
Hydraulic oil temperature:45 55C
q
Measuring main relief pressure

1.
2.
Fit frame lock bar (1) between front frame and

rear frame.
Remove oil pressure pickup plug (2) of the

steering cylinder circuit.
30-120
12

Testing and adjusting steering oil pressure
Adjusting main relief pressure

1.
2.
Stop the engine.

Remove cover (1) at the lower right of the
operator's cab.
3.
Disconnect hose (3) and fitting (4) connected

to port (T) of the priority valve (2).
SEN03935-02
4.
Loosen lock screw (5), and then turn adjustment screw (6) to adjust.
q
CLOCKWISE.
q
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 accurately.
3 Adjustment screw (6):
2.3 6.8 Nm {0.23 0.69 kgm}
3 Lock screw (5):
14.7 2 Nm {1.5 0.2 kgm}
5.

30-120
13
SEN03935-02

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 piston to the end of its stroke to relieve the circuit.
30-120
14

SEN03935-02
3.
Install tachometer P1 to the tripod.

a Set tachometer P1 perpendicular to reflector tape [1].
4.
Start the engine, run at high idle, and measure

the fan speed.
5.

Necessary tools
Symbol
1
Q
2
3
a
a
Part No.
Part Name
799-205-1100
Tachometer KIT
799-101-5002
790-261-1204
799-401-3400
Adapter
02896-11015
O-ring

When removing the measurement plug and
disconnecting the hose, loosen the oil filler
cap slowly to release the pressure inside
the hydraulic tank.
q
Test the fan in a place where the fan blade and
probe will not be exposed to direct sunlight or
strong light.
Testing fan speed

1.
Open the radiator grille.
2.
Stick reflector tape [1] of tachometer P1 to a

metallic part of the fan.
30-120
15

SEN03935-02
Testing fan drive oil pressure
1.
Open the radiator grille.
2.
Remove the fan motor cover (1).
3.
4.
Start the engine and measure the fan drive oil

pressure.
5.

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

Measuring brake pedal
Measuring brake pedal

a
q
q
SEN03935-02
Engine coolant temperature: Within green
range on engine coolant temperature gauge
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}.
30-120
17
SEN03935-02

Testing and adjusting brake pedal linkage
Testing and adjusting brake pedal

linkage
1
Testing
1.
Check for play in linkage mounting pin (7), pinhole 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 standard 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

Measuring brake performance
SEN03935-02
Measuring brake performance
9JF01100
q
Road surface:
q
Travel speed:
35 km/h when brakes are applied
q
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, determine 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.
30-120
19

Testing and adjusting accumulator charge pressure
SEN03935-02

accumulator charge pressure
Necessary tools
Symbol
Part No.
Part Name
799-101-5002
790-261-1204
R
k

Measuring
4.
q

Stop the engine, then depress the brake
pedal at least 100 times to release the pressure inside the accumulator circuit.
1.
Remove the rear frame left side cover (1).
Measure the accumulator charge cut-in pressure. Start the engine, run the engine at low
idle, and measure the oil pressure when the
brake pressure caution lamp on the monitor
panel goes out.
q
Cut-in pressure:
+2
5.9 +0.2
0 MPa {60 0 kg/cm }
2
5.
Measure the accumulator charge cut-out pressure.

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
MPa {100 +10
0
0 kg/cm }
2
6.
2.
Remove plug (2).
3.
Install measurement nipple and oil pressure

gauge R (40 MPa {400 kg/cm2}).
30-120
20


Testing and adjusting accumulator charge pressure
SEN03935-02
Adjusting
a
When the accumulator charge cut-out pressure 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 (accumulator charge cut-out valve) (3), then turn
q
To RAISE pressure, turn CLOCKWISE
q
To LOWER pressure, turn COUNTERCLOCKWISE
2.
After adjusting, tighten locknut (4).

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.
30-120
21

Testing wheel brake oil pressure
SEN03935-02

a
2.
Remove brake tube (2) of the measured side.

a The right side is shown as an example in
the figure.
3.
Remove union (3) and install adapter S4 and

nipple S5.
a Use the O-ring fitted to the union.
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.
Necessary tools
Symbol
Part No.
Part Name
1 793-605-1001 Brake test kit

2 790-101-1430 Coupler
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
a
a
1.
793-463-1100 Stopper

Apply the parking brake.
Measure the oil pressure of the front brakes
(right and left) and rear brakes (right and left)
similarly.
Measuring condition.
q
q
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.
30-120
22

SEN03935-02
Composition and connection diagram of brake test kit S
30-120
23
SEN03935-02
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 minutes and check lowering of the pressure.
a If the hose is moved while the pressure is
m ea s u re d , t h e p re s s u re f l u c t u at e s .
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.
8.

30-120
24


Testing wear of brake disc
Testing wear of brake disc

k
SEN03935-02

There are caps for inspection on the right and
left sides of the front and rear axles. Check at
all of the 4 caps similarly.
1.
Remove cap (1) from the axle housing.
2.
Press the brake pedal to the stroke end.
3.
With shaft (2) pushed in, measure projection

(x) from surface (a) of guide (3) (wear).
a Keep pressing the brake pedal while measuring the wear.
a If shaft (2) is projected from the end of
guide (3) to the groove, replace the disc.
q
Wear: (x) from (a)
q
Wear limit: (y) from (a) (1.6 mm)
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}
30-120
25

Bleeding air from wheel brake circuit
SEN03935-02
Bleeding air from wheel brake

circuit
3.
Connect hose [1] to bleeder screw (2) and

place hose [1] in the oil receive pan.
a Work on the rear side similarly from underside of the machine.
4.
Press the brake pedal and then loosen bleeder

screw (2) to bleed air.
a Return the brake pedal slowly after tightening bleeder screw (2).
5.
Repeat this operation until the oil flowing

through hose [1] becomes free from bubbles.
Then press the pedal fully and tighten bleeder
screw (2) while the oil is flowing.
a As accumulated pressure in the accumulator is decreased, start the engine to
accumulate pressure in the accumulator.
Then bleed air using the same procedure
as described above.
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.
6.

Necessary tools
Symbol
T
k
a
a
a
a
Part No.
Part name
793-463-1100 Stopper

If a brake circuit part is removed and installed,
bleed air from the brake circuit according to the
Bleed air from the front brake circuit and rear
brake circuit similarly (2 places each).
When a complete bleeding is required, it is
advisable to start the operation from the brake
cylinder situated farthest from the brake pedal.
The work on the front right side is shown as an
example. Work on each brake cylinder similarly.
1.
Start the engine to accumulate pressure in the

accumulator and then stop the engine.
2.

k When raising the lift arm and removing
the inspection cover, place support
stand [1] under the lift arm to support
the lift arm securely or set stopper T to
the lift arm cylinder to prevent the work
equipment from falling.
30-120
26

Releasing residual pressure in brake accumulator circuit
Releasing residual pressure in

brake accumulator circuit
k
q
q
SEN03935-02
Before disconnecting any of the following

brake accumulator circuits, release residual pressure in that brake circuits.
Piping between accumulator charge valve and
brake accumulator
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 accumulator circuit.
30-120
27

Testing parking brake performance
SEN03935-02
Testing parking brake

performance
a
Measurement condition
q
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

Testing and adjusting parking brake control cable
Testing and adjusting parking

brake control cable
SEN03935-02
Necessary tools
Symbol
Part No.
79A-264-0021
Part Name
Push-pull scale

Testing
1. Install push-pull scale V to a position at dimension (a) from the end of parking brake lever (1)
(excluding the button) and pull it with a force of
about 294 N {about 30 kg}.
q
Dimension (a): 55 mm
2.
Adjusting
1. Release the parking brake.
a Check that the pawl of the parking brake
lever is at the lowest position.
If the parking brake lever is pulled by 9 teeth or

more, check the fixing parts of the parking
brake control cable (on both lever side and
brake side) for looseness. If the fixing parts are
loosened, tighten them, and then perform the
following adjustment.
2.
Loosen locknut (2) and remove clevis pin (3).
3.
Pull parking brake lever (4) on the transfer side

in the release direction. (Add the play of the
parking brake lever to the upper side, however.)
4.
Under the above condition, tighten clevis (5) to

match its hole to the hole of parking brake
lever (4).
5.
Install clevis pin (3) and tighten locknut (2).

3 Locknut: 5.9 9.8 Nm {0.6 1.0 kgm}
a After finishing adjustment, pull parking
brake lever (1) again with a force of about
294 N {about 30 kg} and check that it travels 7 8 clicks.
30-120
29

Measuring and adjusting work equipment control lever
SEN03935-02
Measuring and adjusting work

equipment control lever
Necessary tools
Symbol
k
q
q
q
Part Name
79A-264-0021
Push-pull scale
Commercially
available
Scale
Part No.
Measuring travel of work equipment control

lever
Measure the travel at each position when operating
the work equipment control lever.
a Mark the lever knob and use a scale W2 to
measure.
a If the stroke is not within the standard value,
check for play in the work equipment PPC
valve.
Install the frame lock bar to the frame.

Measuring condition
of engine coolant thermometer
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 minimum value for the effort needed to operate the
knob.
30-120
30

Testing and adjusting work equipment hydraulic pressure
Testing and adjusting work

equipment hydraulic pressure
Adjusting
1
Necessary tools
Symbol
Part No.
Part Name
799-101-5002
790-261-1204
793-463-1100
Stopper
SEN03935-02
a
k
X
T
k
Always stop the engine before adjusting the oil

pressure.
When carrying out the operation with the
lift arm raised, set support [1] or lift arm
drop prevention stopper T in position
before starting the operation.
1.
2.
Remove cap nut (2) of relief valve (5).
3.
Loosen locknut (3) of relief valve (5), then turn

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 accurately.
4.


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.
2.
Install hydraulic tester X (40 MPa {400 kg/cm2})

to the oil pressure measurement nipple.
Start the engine, raise the lift arm approx. 400

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.
30-120
31

Testing work equipment PPC oil pressure
SEN03935-02
Testing work equipment PPC oil

pressure
Necessary tools
Symbol
Part No.
Part Name
799-101-5002
790-261-1204
793-463-1100
Stopper
Y
T
k
Checking PPC valve output pressure

1. Remove the inspection cover (1) of the front
frame.
k Except for measuring the oil pressure,
when carrying out preparatory operations
with the lift arm raised, set support [1] or
lift arm drop prevention stopper T in position before starting the operation.

the pressure inside the hydraulic tank.
Then operate the control levers several
times to release the pressure in the piping.
Measuring condition
When leaving the operator's seat, apply the

work equipment lock lever securely.
Testing PPC valve basic pressure

1. Remove plug (4) (10 mm, P = 1.25 mm) for
measuring the work equipment PPC valve
basic pressure (same as low-pressure relief
pressure) from under the machine.
2. Fit a nipple, then install oil pressure gauge Y (6
MPa {60 kg/cm2}).
3. Start the engine.
4. Run the engine at high idle, then operate the
work equipment control lever and measure the
oil pressure.
5.
2.
3.
4.
Remove PPC output pressure measurement

plug of the circuit to be measured, then install
oil pressure gauge Y (6 MPa {60 kg/cm2}).
Start the engine, then remove support [1] or
boom drop prevention stopper T.
Operate the work equipment control lever at
high idle and measure the oil pressure.

30-120
32

Testing work equipment PPC oil pressure
5.
SEN03935-02
A: Bucket TILT
B: Bucket DUMP
C: Lift arm RAISE
D: Lift arm LOWER

30-120
33

Bleeding air from hydraulic circuit
SEN03935-02
Bleeding air from hydraulic

circuit
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 circumstances.
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

Releasing remaining pressure in hydraulic circuit
Releasing remaining pressure in

hydraulic circuit
SEN03935-02
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 follows.
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 accumulator 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 pressure 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 accumulator circuit.
Releasing remaining pressure in PPC accumulator circuit
a If the piping between the PPC accumulator
and PPC valve is to be disconnected, release
the remaining pressure from the circuit as follows.
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.
30-120
35

Testing and adjusting bucket positioner
SEN03935-02
Testing and adjusting bucket

positioner
a
2)
1
Measuring condition
q
Engine coolant temperature: White range
of engine coolant thermometer
q
Testing
1. Stop the engine and check that clearance (a)
between proximity switch (1) and detection bar
(2) is in the standard range.
a Standard clearance (a): 3 5 mm
2.
Run the engine at same as usual working

speed and check the operating point. (Measure 3 times and obtain the average.)
2.
Adjust and secure clearance (a) between

the sensitive surface of proximity switch
(1) and detection bar (2) to the standard
range with the shim and mounting bolt of
the proximity switch bracket.
a Adjust detection bar (2) with the shim
so that clearance (a) will be in the
standard range through the stroke of
the detection bar (2).
Adjusting installing position (stopping

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
position.
a For ON/OFF of the pilot lamp, see
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 sensitive 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}
30-120
36
After adjusting, start the engine and operate the work equipment control lever to
check that the bucket positioner sets the
bucket at the desired position.

Testing and adjusting of boom kick-out switch
Testing and adjusting of boom

kick-out switch
SEN03935-02
4.
1
Testing
1.
With the engine stopped, check that clearance

(a) between detection surface of switch (1) and
plate (2) is the standard value.
2.
Start the engine, run at high idle, and check the

actuation point.
(Check three times and take the average.)
Adjust the switch so that clearance (a) between

the sensing surface of the switch and plate (2)
is 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 position.
a For ON/OFF of the pilot lamp, see Checking 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.
Adjusting
1.
2.
3.
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 bottom of the plate.
Always be sure to apply the work equipment
lock lever.
Lower the lift arm and stop the engine.
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).
30-120
37

Checking proximity switch operation pilot lamp
SEN03935-02
Checking proximity switch

operation pilot lamp
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)
Proximity switch
Bucket positioner
Boom kick-out
30-120
38
Positional relationship between sensitive surface

of proximity switch and sensing object
Operation pilot lamp
Remarks
Near
ON
Operates when center of

switch is near
Far
OFF
Near
ON
Far
OFF
Operates when center of

switch is far

Procedure for testing diodes
Procedure for testing diodes

a
a
SEN03935-02
Check an assembled-type diode (8 pins) and

independent diode (2 pins) in the following
manner.
The conductive directions of the assembledtype diode are indicated on the surface of the
diode as shown in the following figure.
2.
The conductive directions of the single diode is

indicated on the surface of the diode as shown
in the following figure.
1.
When using digital type circuit tester

1) Switch the testing mode to diode range
and confirm the indicated value.
a Voltage of the battery inside is displayed 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 indicated 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 indicated for silicon diodes.
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
() to the cathode (N) of diode.
2] Apply the red (+) lead of the tester to
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, however, wh en the conn ectio n 2 ] is
employed. Normal (However, magnitude of the pointer's move (indicating
the resistance value) varies depending on the given tester model and the
measurement range selected).
q
The pointer swings with both the connections of 1] and 2]: Defective (Internal short circuit)
q
The pointer does not swing with both
the connections of 1] and 2]: Defective (Internal breaking of wire)
30-120
39

Preparation work for troubleshooting for electric system
SEN03935-02
Preparation work for

troubleshooting for electric
system
a
1.
When carrying out troubleshooting for an electric circuit related to the machine monitor,
transmission controller, work equipment controller, or KOMTRAX terminal, expose the
related connectors according to the following
procedure.
Disconnect and connect the connectors of special lock types according to the following procedure.
Machine monitor
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
a Pull the switch out of the cover and
disconnect each connector.
a If you insert your hands from under
the cover and disconnect a connector
forcibly, you many damage the connector or switch. Take care.
30-120
40
2)
Remove cover (1).
3)
Remove 3 bracket mounting bolts (3) of

machine monitor (2) and reverse the
machine monitor.
a Take care not to pull the wiring harness forcibly.

4)
2.
Connect diagnosis T-adapters to connectors L24 to L30 of machine monitor (2).
HST controller
1) Remove cover (1) from the rear of the cab.
2)
SEN03935-02
3.
KOMTRAX terminal
1) Open right door (1) and remove console
cover (2).
2)
Connect diagnosis T-adapter to connector L80 of KOMTRAX terminal (3).

a If the connector cannot be disconnected 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}
Connect diagnosis T-adapters to HST

connector of HST controller (2).
30-120
41
SEN03935-02
4.
Boost pressure and temperature sensor

(BOOST PRESS & IMT)
a Disconnection and connection of connector
The connector of the boost pressure and
temperature 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:
(c) Connect connector (d) Lock.
5.
Removal and installation of sensor

A torque wrench is necessary for removal
and installation of the boost pressure and
temperature sensor. See Testing adjusting, Troubleshooting tools table.
Supply pump IMV solenoid (FUEL REGULATOR)

The connector of the supply pump IMV
solenoid has a special locking mechanism. Disconnect it according to steps (a)
(b) and connect it according to steps (c)
(d) as shown below.
Disconnection:
Connection:
30-120
42

6.
Common rail pressure sensor (FUEL RAIL

PRESS)
The connector of the common rail pressure 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:
Connection:
Precautions for disconnecting connector

The direction of the lock of the connector
varies with the tightened position of the
sensor and the lock may be in a direction
in which it is difficult to reset (on the underside or engine side).
In this case, pinch the lock in direction (a)
with bent-nose nippers (commercially
available), and the lock is reset.
Since the lock clicks when it is reset, disconnect the connector after a click is
heard.

7.
Precautions for connecting connector

Take care not to connect the connector
reversely.
Engage lock (e) on the wiring harness
side with triangular notch (f) on the sensor
side (Do not engage lock (e) with square
guide (g) on the opposite side of triangular
notch (f)).
Engine coolant temperature sensor (COOLANT TEMP)

The connector of the engine coolant temperature 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:
Connection:
SEN03935-02
8.
Ambient pressure sensor (AMBAIR PRESSURE)

Engine Ne speed sensor (CRANK SENSOR)
Engine Bkup speed sensor (CAM SENSOR)
Engine oil pressure switch (OIL PRESSURE
SWITCH)
a Disconnection and connection of connectors
The connectors of the ambient pressure
sensor, engine Ne speed sensor, engine
Bkup speed sensor, and engine oil pressure switch have a special locking mechanism. 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.

A deep socket is necessary for removal
and installation of the engine oil pressure
switch. See Testing adjusting, Troubleshooting tools table.

A deep socket is necessary for removal
and installation of the engine coolant temperature sensor. See Testing and adjusting, Troubleshooting tools table.
30-120
43

Starting KOMTRAX terminal operations
SEN03935-02
Starting KOMTRAX terminal

operations
3)
When about 5 seconds elapsed after the

starting switch was set to ACC, make sure
that the 7-segment indicator lamp
changes to hyphen on the KOMTRAX
terminal.
4)
Disconnect check connector 1, and wait

for about 3 to 5 seconds as it is.
a Ensure that the connector is disconnected.
Reconnect check connector 1, and wait
for about 5 seconds as it is.
a If the KOMTRAX terminal detects that
the connector was disconnected and
connected, the dot on the 7-segment
indicator lamp blinks a few times.
In the case where the KOMTRAX terminal has

already been installed at the plant before shipment:
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 operations administrator for the procedure.
a Now the terminal is ready for use.
In the case where the KOMTRAX terminal is retrofitted:

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 seconds. If 60 seconds or above elapsed,
begin with step 1) again.
1) Turn OFF the starting switch and then,
after making sure 5 seconds have
elapsed, proceed to the next step.
2) Visually check that two check connectors
are connected.
q
Check connector 1: CHK0
q
Check connector 2: CHK1
30-120
44
5)

6)
SEN03935-02
a
Make sure that the 7-segment indicator

lamp is indicated normally on the
KOMTRAX terminal.
a If so, the 7-segment indicator lamp will
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 seconds or above elapsed.
The display may change to a character other than 0 even within 30 seconds.
7)
8)
9)
As [Normal] is indicated, proceed to

the next step.
If remains displayed, execute
steps 1) to 5) again.
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.
Turn the starting switch from ACC position
to START position again, and make sure
that the engine starts.
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 trouble] 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 communication antenna/cable. If there is any
abnormality, repair it and start from
procedure 1) again.
30-120
45
SEN03935-02
a
If [Network trouble] is indicated,

check the display of [LED-C4] referring to Lamp display of KOMTRAX
terminal. If the CAN is not recognized, check the CAN harness of the
KOMTRAX terminal, and then if there
is any abnormality, repair it and start
from procedure 1) again.
[A]: Normal
[B]: GPS position data detection trouble
[C]: Reception trouble
[D]: GPS position data detection trouble and reception trouble
[E]: Network trouble

10) Turn the starting switch OFF.

11) Make sure that the 7-segment indicator
lamp is displayed normally after 5 seconds
elapsed.
a When [Normal] appears, station
opening check is completed.
a If [Abnormal] appears, station opening check does not end normally, so
you should perform the procedure
above from step 1) again.
a If station opening check ends normally, it should not be rechecked.
12) When station opening check ended norm 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 communication 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

2.
SEN03935-02
Application for the start of use

a Application for the start of use should be
made only after the sign-up test is finished.
1) Notify the KOMTRAX operations administrator 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 register the machine.
a Refer to Manual for KOMTRAX operations administrator for the procedure.
a Now the terminal is ready for use.
30-120
47

Indicator lamps of KOMTRAX terminal
SEN03935-02
LED lamps for CPU

1. LED-C1 (State of R or ACC signal)
2. LED-C2 (Starting output 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
7-segment and dot displays for CPU

7. 7 segments (Number of unsent mails)
8. Dot (GPS positioning state)

SEN03935-02
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.
No.
LED
Name/function
Display
(*1)
ON
States of starting switch
Fast blink
LED-C1 ACC signal and alternator R
Slow
blink
signal
OFF
LED-C2 State of engine control signal
LED-C3
ON
LED-C6
Starting switch ACC signal: OFF, Alternator R signal: ON

Starting switch ACC signal: ON, Alternator R signal: OFF
Starting switch ACC signal: OFF, Alternator R signal: OFF
Engine control signal: ON
OFF
Engine control signal: OFF
ON
S-NET: Connected, Starting switch C signal: OFF
OFF
S-NET: Not connected, Starting switch C signal: OFF
ON
CAN: Connected (without fuel sensor)
Fast blink CAN: Connected (with fuel sensor)

Slow blink CAN: Not connected (with fuel sensor)
OFF
LED-C5
Starting switch ACC signal: ON, Alternator R signal: ON
States of S-NET connection Fast blink Starting switch C signal: ON

and starting switch C signal Slow blink (Not used)
LED-C4 State of CAN connection
Description
CAN: Not connected (without fuel sensor)
1-LED ON Download write mode (system administrator only function)

Download write state
2-LED
OFF
Normal operation mode
*1: Blink types and blink times

Fast blink: Blinks in about 1-second cycle
Slow blink: Blinks in about 4-second cycle
30-120
49

SEN03935-02
2.
a
Contents of 7-segment and dot displays for CPU

The LED display should be checked with the starting switch turned ON.
No.
LED
7 segments
Dot
Name/function
Number of unsent
mails, satellite
capture state
GPS positioning
status
Display
(*2)
Description
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
displayed
machine is in process of capturing the satellite.
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.
ON
GPS positioning was completed. (The position can be confirmed. *3)
OFF
GPS positioning was not completed. (The position cannot be

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

SEN03935-02
30-120
51
SEN03935-02

2009 KOMATSU
All Rights Reserved
30-120
52
SEN03936-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
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 ............................................................................................................................. 60
30-130
SEN03936-01

Adjusting machine monitor
Adjusting machine monitor
Layout of rotary switches (SW1, SW2, and SW3) and DIP switches (SW5 and SW6)
q
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.
The switches shown in the figure are set as when the monitor is delivered.
30-130

Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
SEN03936-01
Adjusting replaced, reassembled or added sensor, controller, etc. with

machine monitor
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
Addition or removal of option
Adjustment item
Contents of adjustment
Description No.
Selection of machine model
12 (*1)
Selection of option
10 (*1)
Inputting of machine serial No.
11 (*1)
*1: Description No. of Service mode in Special functions of machine monitor (EMMS)
30-130
SEN03936-01
2.

Adjusting replaced, reassembled or added sensor, controller, etc. with machine monitor
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)
Turn ECO lamp OFF
Change interval of fan automatic reverse operation (Automatic reverse fan specification)
Change continuance of fan automatic reverse operation (Automatic reverse fan specification)
Travel speed is indicated too quickly/slowly
Turn engine speed/travel speed on character display OFF
ECSS operates at high or low travel speed
Change display of major indication in engine speed (*3)
Adjustment item
Contents of change/adjustment
Description No. (*1)
Setting of option/Selection of speed unit (*2)
10
Setting of option/Selection of indication of ECO lamp
10
Adjustment of sensor/Adjustment of interval of fan automatic

reverse operation
71
Adjustment of sensor/Adjustment of continuance of fan automatic

reverse operation
72
Setting of option/Change of tire size
10
Setting of option/Change of indication of engine speed or travel

speed on normal screen of character display
10
Adjustment of ECSS operation travel speed
75
Travel speed/engine speed display/non-display select
No. 10 of
"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

Special functions of machine monitor (EMMS)
SEN03936-01

a
EMMS: Equipment Management Monitoring System
1.
2.
3.
Machine monitor mode change switch 1

Machine monitor mode change switch 2
Character display
30-130

SEN03936-01
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 display 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 inspection, maintenance, and troubleshooting.
No.
(*1)
No.
(*1)
Operator mode
Service mode
Service meter display function
Electrical system fault history display function
Traction level selection function
Mechanical system fault history display function
HST function selection function
Odometer display function
Engine cylinder cut-out function
Telephone number input function
Adjustment function
Language selection function
Monitor brightness adjustment function
Travel speed/engine speed display selecting

function (*2)
10
Optional device selecting function
10
Function of turning ON/OFF travel speed/

engine speed display on character display (*3)
11
Machine serial number input function
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

SEN03936-01
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.)
30-130
SEN03936-01
30-130


SEN03936-01
30-130

SEN03936-01
Operator mode
a
a
The operator mode is outlined below.

For details of the operator mode, see Structure, function and maintenance standard or
Operation and Maintenance Manual.
1.
Service meter display function

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.
2.
3.
HST function selection function

While the speed range selector switch is in the
3rd or 4th gear speed position, the reverse
speed range can be set to 2 levels.
a For details, see Operation and Maintenance Manual, Operation, Other functions of machine monitor.
4.
Odometer display function

The odometer is displayed.
Traction level selection function

Press [U] switch on the ordinary service meter
display screen, and the screen to set the traction 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
a
30-130
For items 3 and after, display a desired

screen with [<] or [>] switch on the Traction level selection function screen.
Each time [<] or [>] switch is pressed, the
screen changes in order. Repeat either
switch until a desired screen is displayed.
10

5.

1) Filter, oil replacement time display (automatic display)
As the filter or oil replacement time draws
close, the machine monitor automatically
displays its information to alert operator's
attention.
2) Resetting replacement time (selection
menu)
As maintenance operation for a filter or oil
is completed, the machine monitor allows
resetting the time interval through the
switch operation.
a For details, see the Other functions
of machine monitor of the Operation section in the Operation and
maintenance manual.
6.
Telephone number input function

Telephone numbers are entered through the
switch operation. And modification or cancellation 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 manual.
SEN03936-01
7.
Language selection function

Switch operation allows selecting a display language of the machine monitor.
a Functions of the service mode are constantly displayed in English since they are
exempted from the display selection function.
a A desired language is selectable from
English, Japanese, German, French, Italian, Spanish and Swedish.
30-130
11

SEN03936-01
8.
Monitor brightness adjustment function

Brightness of the machine monitor is adjustable
in seven levels through the switch operation.
a Adjustment of brightness is available in
two approaches adjustment of the monitor alone and separate adjustment of the
monitor and liquid crystal.
9.
Travel speed/engine speed display selecting function

A unit to be used for the machine monitor
speed display is selectable from km/h and
MPH. It is also possible to turn on or off the display of the travel speed and engine speed.
10. Travel speed/engine speed display/non-display selecting function

A unit for the machine monitor speed display is
selectable from km/h and MPH. It is also possible to turn on or off display of the travel speed
and engine speed.
30-130
12

SEN03936-01
11. Action code display function

If a trouble occurs, the machine monitor displays an action code corresponding to the seriousness 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 alternately displayed.
a When action code [E01] or [E02] is displayed, [CALL + Telephone number] is not
displayed.
Action codes and actions alerted to operator

Action code
CALL + Telephone number
E01
Not displayed
Do necessary testing and/or servicing as the current work is over or at

shift of the operator.
E02
Not displayed
When an overrun-related item is displayed:

Slow down the engine or machine speed.
When an overheat-related item is displayed:
Stop the machine and run the engine at mid speed with no load.
E03
Displayed
Actions recommended to operator
Stop the engine and machine immediately and contact a serviceman.
30-130
13

SEN03936-01
12. Failure code display function
Pressing [>] switch once while an action is displayed on the machine monitor displays the
failure code corresponding to the failure currently warned.
a The failure codes detected in the past are
divided into failures of the electrical system and the mechanical system and are
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 displays the failure codes from the first.
If [>] switch is not touched for 30 seconds,
the action code display screen is automatically displayed.
The service code display function displays

the following information.
A: Failure code
B: Controller code
MON: Machine monitor
HST: HST controller
ENG: Engine controller
C: The system where failure occurred
For details of a displayed failure code, see

Failure code list.
If any switch operation is not done for 30
seconds or more on the failure code display screen, the action code display
screen is automatically turned on.
30-130
14

Service mode
1.
Procedure for switching to Service mode

and screen display
Reference: The service meter is displayed in
English, regardless of language
selection in the operator mode.
When using Service mode, carry out the following special operation to switch the screen
display.
1-1. Checking screen display
Make sure that the machine monitor is set to
the operator mode and any of Service meter,
Action code or Failure code is displayed on
the screen.
1-2. Displaying ID input initial screen
Hold down [t] switch and [<] switch simultaneously for 5 seconds minimum to open ID
input initial screen.
a Holding down the two switches for 5 seconds or more makes the entire screen
blank. As this state is recognized, release
the buttons.
SEN03936-01
(*1): When the cursor is located at the leftmost position, pressing the switch
restores the normal screen (Operator
mode).
When the cursor is at a location other
than the leftmost position, pressing
the switch returns the cursor to the
leftmost position.
If any switch operation is not done for
60 seconds or more from ID input
screen, the normal screen is automatically turned on.
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 highestorder 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
press [U] switch.
a When you have entered a wrong value to
a position except the highest-order digit,
move to the highest-order digit using [t]
switch to repeat the procedure from the
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. (*1).
1-5. Selecting service mode menu

a Pressing [<] and [>] switches from the
menu screen displays Service mode
menus endlessly in the following order.
a The menus are displayed in the field indicated with [*] mark.
[1] ELECTRIC FAULT: Electrical system
fault history display function
[2] MACHINE FAULT: Mechanical system fault history display function
[3] REAL-TIME MONITOR: Real-time
monitoring function
30-130
15

SEN03936-01
[4] CYLINDER
CUT-OUT:
Engine
reduced-cylinder function
[5] NO INJECTION: No injection cranking function
[6] TUNING: Adjustment function
[7] MAINTENANCE MONITOR: Maintenance monitoring function
[8] OPERATION INFO: Operating information display function
[9] OPTIONAL SELECT: Optional device
selecting function
[10] MACHINE No. SET: Machine serial
number input function
[11] MACHINE: Model selection function
[12] INITIALIZE: Initialize function (Function specialized for plant)
The menu is indicated in the parts of [*].
2.
Electrical system fault history display function (ELECTRIC FAULT)

The machine monitor records the past failures
in the electric system as the failure codes. The
failure codes are displayed from the following
operations.
2-1. Selecting the menu
Select the ELECTRIC FAULT from the menu
screen of Service mode.
a [**] field displays total number of the fault
history currently recorded (up to 20
cases).
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 necessary).
2) When ending an operation completely:
Turn the starting switch off from the current state.
30-130
16
2-3. Displayed fault history

The electric system fault history display function displays the following information.
A: Record number
B: Failure code (Location code in four digits +
Problem code in two digits)
C: Number of occurrences (number of occurrences 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.

a
a
For details of a displayed failure code, see

Failure code list of the failure code display function.
Note that part of the information displayed
from the electrical system fault history display function and the failure code display
function is not identical.
When the requested fault history is not
recorded, [] is indicated in the display
space.
SEN03936-01
2-6. Deleting all fault history
1) Press [<] or [>] switch while the fault history is on the screen to display the ALL
CLEAR menu screen.
2)
3)
a
2-4. Switching fault history display
Pressing [<] or [>] switch while a set of fault
history is on the screen displays another set of
recorded fault history.
2-5. Deleting individual fault history
1) Press [U] switch while the target fault history of deletion is on the screen to turn on
CLEAR screen.
2) Select YES or NO using [<] or [>] switch.
a The selected cursor will start flashing. If
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 failure is not deletable.
a
a
Press [U] switch to display the ALL

CLEAR screen.
Select YES or NO using [<] or [>]
switch.
The selected cursor will start flashing. If
YE S is s elec ted a nd [t] s witc h is
Maintenance interval change item
screen is restored.
By default, the cursor is set to NO (cancel)
Information of the currently occurring failure is not deletable.
30-130
17

SEN03936-01
3.
Mechanical system fault history display

function (MACHINE FAULT)
The machine monitor records the past failures
in the mechanical system as the failure codes.
The failure codes are displayed from the following operations.
a Select MACHINE FAULT from the menu
screen of Service mode.
a [**] field displays total number of the fault
history currently recorded.
3-3. Displayed fault history

The mechanical system fault history display
function displays the following information.
A:
B:
Record number
Failure code (Location code in four digits +
Problem code in two digits)
C: Number of occurrences (number of occurrences of same code in past)
D: Occurrence time 1 (Time on service meter
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 display 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

SEN03936-01
Failure codes table

Failure
code
Troubled part/item
Trouble
Controller
Action
code
Category of
record
2G40ZG Brake
Oil pressure reduction
MON
E03
Mechanical
system
6091NX
HST filter
Clogging
MON
E01
Mechanical
system
989FN1
Travel speed
Overrun alarm
MON
E02
Mechanical
system
AA1ANX Air cleaner
Clogging
MON
E01
Mechanical
system
AB00L6
Hot short
MON
E01
Electrical
system
AB00MA Alternator R system
Ground fault/Disconnection/Low
charge level
MON
E03
Electrical
system
B@BAZG Engine
ENG
E03
Mechanical
system
B@BAZK Engine oil
Low oil level
MON
E01
Mechanical
system
B@BCNS Engine
Overheat
ENG
E02
Mechanical
system
B@BCZK Engine
Low coolant level
MON
E01
Mechanical
system
B@C6NS Front brake
High oil temperature
MON
E02
Mechanical
system
B@CRNS HST
MON
E02
Mechanical
system
Alternator R system
CA111
Engine controller
Internal abnormality
ENG
E03
Electrical
system
CA115
Engine NE, Bkup speed sensor
Abnormality
ENG
E03
Electrical
system
CA122
Charge pressure sensor
Abnormally high level
ENG
E03
Electrical
system
CA123
Abnormally low level
ENG
E03
Electrical
system
CA131
Throttle sensor
ENG
E03
Electrical
system
CA132
Throttle sensor
ENG
E03
Electrical
system
CA144
Coolant temperature sensor
ENG
E01
Electrical
system
CA145
Coolant temperature sensor
ENG
E01
Electrical
system
CA153
Charge temperature sensor
ENG
E01
Electrical
system
CA154
Charge temperature sensor
ENG
E01
Electrical
system
CA155
Charge temperature
Abnormally high speed derate
ENG
E03
Electrical
system
CA187
Sensor power supply 2
ENG
E03
Electrical
system
CA221
Ambient pressure sensor
ENG
E01
Electrical
system
30-130
19

SEN03936-01
Failure
code
Troubled part/item
Trouble
Controller
Action
code
Category of
record
CA222
ENG
E01
Electrical
system
CA227
ENG
E03
Electrical
system
CA234
Engine
Overspeed
ENG
E02
Mechanical
system
CA238
Ne speed sensor power supply
Abnormality
ENG
E03
Electrical
system
CA271
IMV (IMA)
Short circuit
ENG
E03
Electrical
system
CA272
IMV (IMA)
Disconnection
ENG
E03
Electrical
system
CA322
Injector #1 system
Disconnection/Short circuit
ENG
E03
Electrical
system
CA323
Injector #5 system
ENG
E03
Electrical
system
CA324
Injector #3 system
ENG
E03
Electrical
system
CA325
Injector #6 system
ENG
E03
Electrical
system
CA331
Injector #2 system
ENG
E03
Electrical
system
CA332
Injector #4 system
ENG
E03
Electrical
system
CA342
Engine controller
Data mismatching
ENG
E03
Electrical
system
CA351
Injector drive circuit
Abnormality
ENG
E03
Electrical
system
CA352
ENG
E03
Electrical
system
CA386
ENG
E03
Electrical
system
CA428
Water sensor
ENG
E01
Electrical
system
CA429
Water sensor
ENG
E01
Electrical
system
CA431
Idle validation switch
Abnormality
ENG
E01
Electrical
system
CA432
Abnormal remedy
ENG
E03
Electrical
system
CA435
Engine oil pressure switch
Abnormality
ENG
E01
Electrical
system
CA441
Power supply voltage
ENG
E03
Electrical
system
CA442
ENG
E03
Electrical
system
CA449
Common rail pressure
Abnormally high pressure 2
ENG
E03
Electrical
system
CA451
ENG
E03
Electrical
system
30-130
20

Failure
code
SEN03936-01
Troubled part/item
Trouble
Controller
Action
code
Category of
record
CA452
ENG
E03
Electrical
system
CA488
Charge temperature
Abnormally high torque derate
ENG
E03
Electrical
system
CA553
Abnormally high pressure 1
ENG
E03
Electrical
system
CA559
Supply pump
Low rail pressure 1
ENG
E03
Electrical
system
CA689
Engine Ne speed sensor
Abnormality
ENG
E03
Electrical
system
CA731
Engine Bkup speed sensor
Abnormal phase
ENG
E03
Electrical
system
CA757
Engine controller
Loss of all data
ENG
E03
Electrical
system
CA778
Abnormality
ENG
E03
Electrical
system
CA1633
KOMNET
Abnormality
ENG
E03
Electrical
system
CA2185
Throttle sensor power supply
ENG
E03
Electrical
system
CA2186
Throttle sensor power supply
ENG
E03
Electrical
system
CA2249
Supply pump
Low rail pressure 2
ENG
E03
Electrical
system
CA2311
IMV (IMA) solenoid
Abnormality
ENG
E03
Electrical
system
CA2555
Intake air heater relay
Disconnection
ENG
E01
Electrical
system
CA2556
Short circuit
ENG
E01
Electrical
system
D160KY
Backup lamp/buzzer relay
Hot short
MON
E01
Electrical
system
D192KY
ECSS solenoid relay
Hot short
MON
E01
Electrical
system
D1B0KA HST safety relay
Disconnection
HST
E03
Electrical
system
D1B0KB HST safety relay
Ground fault
HST
E01
Electrical
system
D1B0KY HST safety relay
Hot short
HST
E03
Electrical
system
D5ZHL6
Ground fault/Disconnection
MON
E01
Electrical
system
DAF3KK UNSW power supply
MON
E01
Electrical
system
DAFRKR Monitor panel CAN-NET signal
Disconnection
HST
E03
Electrical
system
DAJ0KK
HST controller power supply
Low voltage
HST
E03
Electrical
system
DAJ0KT
HST controller memory

(EEPROM)
Abnormality
HST
E01
Electrical
system
IGN C system
30-130
21

SEN03936-01
Failure
code
Troubled part/item
Trouble
Controller
Action
code
Category of
record
DAJ1L4
HST controller main power line
Disconnection/Ground fault
HST
E01
Electrical
system
DAJ1L6
HST controller main power line
Hot short
HST
E01
Electrical
system
DAJ2KK
Controller solenoid power supply Low voltage
HST
E03
Electrical
system
DAJ2L3
HST controller load power supply

Hot short
holding line
HST
E01
Electrical
system
DAJ2L4
HST controller load power supply

holding line
HST
E01
Electrical
system
DAJ5KX
Sensor 5V power supply
Out of input range
HST
E03
Electrical
system
(DAJ9KQ) HST controller
Disagreement in model selection
MON
E03
DAJRKR HST controller CAN-NET
Disconnection in signal line
MON
E03
Electrical
system
Disagreement in option selection
MON
E03
DB2RKR Engine controller CAN-NET
Disconnection in signal line
HST
E03
Electrical
system
DD1NL4 Fan auto reverse switch signal
Abnormality
HST
E01
Electrical
system
DD1NLD Fan reverse switch signal
Abnormality
HST
E01
Electrical
system
DDB6KA Parking brake reminder signal
Disconnection/Hot short
HST
E01
Electrical
system
DDB6KB Parking brake indicator signal
Ground fault
HST
E01
Electrical
system
(DAJRMA) HST controller
DDB6KZ
Parking brake indicator signal or

Trouble
parking brake reminder signal
MON
E03
Electrical
system
DDB6L0
Parking brake reminder signal
Ground fault
HST
E01
Electrical
system
DDB6L4
Parking brake indicator signal
HST
E03
Electrical
system
DDD7KX Travel speed control dial
HST
E01
Electrical
system
DDD7KY Travel speed control dial
Hot short
HST
E01
Electrical
system
Disconnection
MON
E01
Electrical
system
DDK3KA Right direction switch
HST
E03
Electrical
system
DDK3KB Right direction switch
Ground fault
HST
E03
Electrical
system
DDK6KA FNR lever
HST
E03
Electrical
system
DDK6KY FNR lever
Hot short
HST
E03
Electrical
system
DDS5L6
Steering
Low oil pressure (Operation of

emergency steering)
MON
E03
Mechanical
system
DF10KA
Travel speed range selector

switch
HST
E01
Electrical
system
DDE5MA
30-130
Emergency steering operation

switch
22

Failure
code
SEN03936-01
Controller
Action
code
Category of
record
Hot short
HST
E01
Electrical
system
DGH1KX HST oil temperature sensor
Ground fault
MON
E01
Electrical
system
DGR2KB Brake oil temperature sensor
Ground fault
MON
E01
Electrical
system
DGR2KZ Brake oil temperature sensor
MON
E01
Electrical
system
DHH1KX HST oil pressure sensor
HST
E03
Electrical
system
DHH1KY HST oil pressure sensor
Hot short
HST
E03
Electrical
system
DHTCL6 HST filter clogging sensor
Functional defect
MON
E01
Electrical
system
DJF1KA
Fuel level sensor
MON
E01
Electrical
system
DLT3KX
Travel speed sensor B
Abnormality
HST
E03
Electrical
system
DLT4KX
Travel speed sensor A
Abnormality
HST
E03
Electrical
system
DLT4LC
Travel speed sensor A & B
Abnormality
HST
E03
Electrical
system
DV00KY Alarm buzzer
Hot short
MON
E01
Electrical
system
DW26KA Motor 2 solenoid
HST
E01
Electrical
system
DW26KY Motor 2 solenoid
Hot short
HST
E01
Electrical
system
DW7BKY Fan reverse solenoid circuit
Hot short
HST
E01
Electrical
system
DW7BKZ Fan reverse solenoid circuit
HST
E01
Electrical
system
DX16KA Fan EPC solenoid
Disconnection
HST
E01
Electrical
system
DX16KB Fan EPC solenoid
Ground fault
HST
E01
Electrical
system
DX16KY Fan EPC solenoid
Hot short
HST
E01
Electrical
system
DX19KA Motor 1 solenoid
Disconnection
HST
E03
Electrical
system
DX19KB Motor 1 solenoid
Ground fault
HST
E03
Electrical
system
DX19KY Motor 1 solenoid
Hot short
HST
E03
Electrical
system
DX20KA Clutch EPC solenoid
Disconnection
HST
E03
Electrical
system
DX20KB Clutch EPC solenoid
Ground fault
HST
E03
Electrical
system
DX20KY Clutch EPC solenoid
Hot short
HST
E03
Electrical
system
DF10KB
Troubled part/item
Travel speed range selector
switch
Trouble
30-130
23

SEN03936-01
Failure
code
Troubled part/item
Trouble
Controller
Action
code
Category of
record
DXH7KB Reverse solenoid
Ground fault
HST
E03
Electrical
system
DXH7KZ Reverse solenoid
HST
E03
Electrical
system
DXH8KB Forward solenoid
Ground fault
HST
E03
Electrical
system
DXH8KZ Forward solenoid
HST
E03
Electrical
system
J141N1
Steering pump
Overrun alarm
HST
E02
Mechanical
system
M100N1
HST pump
Overrun alarm
HST
E02
Mechanical
system
M400N1
Motor 1
Overrun alarm
HST
E02
Mechanical
system
a
a
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.
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
Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
History classification:
History classification indicates in which system, either electrical system or mechanical system in the failure history display function, a failure has been recorded.
Note: Optional equipments are also included in the table.
30-130
24

4.

(REAL-TIME MONITOR)
The machine monitor checks state of the
machine on real-time basis referencing signals
of the sensors being installed in various parts
of the machine.
The real-time monitoring functions displays following two types of information.
q
1 item independent display
(for each controller)
q
2 items simultaneous display
(code input)
Select REAL-TIME MONITORING from the
menu screen of Service mode.
SEN03936-01
4-3. Selecting sub menu
a Press [<] or [>] switch from the sub menu
screen to display the sub menus endlessly
in the following order.
a The sub menus are displayed in the field
indicated with [*] mark.
[1] MONITOR PANEL: Machine monitor
system
[2] HST: HST controller system
[3] ENGINE: Engine controller system
[4] 2 ITEMS: 2 items display
4-4. Setting the 1 item individual monitoring

1) Select the target controller system of monitoring 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.
30-130
25
SEN03936-01
3)
a
a
a
Press [<] or [>] switch to select a monitoring item.

The monitoring items are scrolled according to the internally set order.
Holding down [U] switch turns on highspeed scrolling.
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.

4-5. Setting 2 items simultaneous monitoring

1) Select 2 ITEMS from the sub menu
screen.
2) Press [U] switch while the sub menu is
selected to display the monitoring code
input screen.
1]
2]
4)
30-130
Display data for 1 item individual monitoring

The 1 item individual monitoring screen
displays the following information.
A: Item display
B: Monitoring codes (5 digits)
1: Monitoring data
(including the unit used)
a See the Real-time monitoring code
list for details.
26
a
3]
a
This cursor (C) is located at the highest-order digit. Pressing [<] or [>]
switch changes the value of this digit
in the range of 0 9.
Press [U] switch when the intended
value appeared to specify it as the set
value.
The cursor moves to the 2nd position.
Set the value in the same order and
then press [U] switch.
When you have entered a wrong
value to a position except the highestorder digit, the cursor can move to the
highest-order digit using [t] switch
and repeat the procedure from the
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.

3)
a
4)
a
SEN03936-01
As both monitoring codes are settled, the

2 ITEMS screen will be turned on.
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.
Display data for 2 items simultaneous

monitoring
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)
See the Real-time monitoring code list
for details.
30-130
27

SEN03936-01
Real-time monitoring codes table
a Use this page in next page and a spread.
MONITOR PANEL [Machine monitor system]

Monitoring item
(*1)
Displayed item
(*2)
Data display range

(*3)
No.
Monitoring code
20200
Monitor software No.
VERSION
20221
Application version No.
VERSION (APP)
Numerals
20222
Data version No.
VERSION (DATA)
Numerals
01001
Engine speed
ENG SPEED
0 4000
40012
Travel speed
SPEED
0.0 50.0
04202
Fuel level
FUEL SENSOR
0 100
04200
Fuel level
FUEL SENSOR
0.00 5.00
04103
Coolant temperature
COOLANT TEMP
40 210
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
Alphanumerals

SEN03936-01
Use this page in front page and spread.

Contents of display in normal state
Unit
(*4)
Remarks
As per software No.
Condition
display
As per software application version No.
Condition
display
As per software data version
Condition
display
Low idle : 800 850 rpm

High idle: 2,200 2,300 rpm
rpm
Data are obtained from HST controller.
F1/R1: 4.0 7.6 km/h

F2/R2: 13.0 18.7 km/h
F3/R3: 18.7 23.6 km/h
F4/R4: 38.0 44.6km/h
km/h
Shown value is max. speed in each speed range.

Value of F1/R1 is speed when travel speed control dial is at min. speed position.
3rd 10th digits from right of part No. are displayed.
0 100% (Depends on fuel level)
Gauge FULL (100%, 10 z): 0.31 V

Gauge 1/2 (50%, 31.1 z): 0.86 V
Gauge 1/4 (25%, 46.8 z): 1.17 V
Caution (80 z): 1.75 V
Gauge EMPTY (0%, 85 z): 1.82 V
When sensor is disconnected or has hot-short: Gauge

EMPTY
When sensor has ground fault: Gauge FULL
Depends on machine condition (C)
Engine coolant temperature: Max. 102C

Data are obtained from engine controller.
Overheat: 105C
Gauge enters red range(105C): 2.07 V

(80C): 2.91 V
When sensor is disconnected or has hot-short: Gauge MIN

When sensor has ground fault: Gauge MAX
(120C): 1.62 V
1(80C): 2.91 V
Depends on machine condition (0.0 30 V)
Depends on machine condition (0.0 30 V)
-----
deg ()
-----
V
a No use these items.
-----
MPa
-----
30-130
29

SEN03936-01
a
Use this page in next page and a spread.

Monitoring item
(*1)
Displayed item
(*2)
Data display range

(*3)
No.
Monitoring code
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
24
30904
DIP switch setting condition
SW5-1, SW5-2
ON/OFF, ON/OFF
25
30905
SW5-3, SW5-4
ON/OFF, ON/OFF
26
30906
SW6-1, SW6-2
ON/OFF, ON/OFF
27
30907
SW6-3, SW6-4
ON/OFF, ON/OFF
28
40900
Input signal D_IN_0-7
D-IN--0------7
See separate table.
29
40901
D-IN--8------15
See separate table.
30
40902
D-IN--16------23
See separate table.
31
40903
D-IN--24------31
See separate table.
32
40904
D-IN--32------39
See separate table.
37
40925
Output signal D_OUT_0-3
D-OUT-0--3
See separate table.
F, F, F
*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

SEN03936-01

Unit
(*4)
-----
MPa
-----
Remarks
a No use these items.

-----
MPa
-----
t
Condition
display
a Do not move from initial position.
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
Condition
display
30-130
31

SEN03936-01

No.
Monitoring
code
40900
40901
40902
40903
Input/Output
signal
Displayed item
Contents of ON/OFF switch
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
D-IN-4
D-IN-5
D-IN-6
Multi-coupler solenoid (Machine with

optional multi-coupler spec.)
Multi-coupler solenoid = ON (24 V)/OFF (OPEN)
D-IN-7
D-IN-8
ECSS switch
(Machine with optional ECSS spec.)
ECSS switch = ON (24 V)/OFF (OPEN)
D-IN-9
Cooling fan automatic reverse switch
Cooling fan automatic reverse setting = ON (24 V)/

OFF (OPEN)
D-IN-10
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
D-IN-16
Brake oil pressure
Normal oil pressure = ON (GND)/OFF (OPEN)
D-IN-17
D-IN-18
D-IN-19
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)
D-IN-28
Omission of applying parking brake
D-IN-29
Engine oil level
Normal oil level = ON (GND)/OFF (OPEN)
D-IN-30
Normal emergency steering

(Machine with optional emergency steering)
Low emergency steering pressure = ON (GND)/OFF

(OPEN)
D-IN-31
*: 1 is displayed when ON and 0 is displayed when OFF.
30-130
32

SEN03936-01

No.
Monitoring
code
40904
40925
Input/Output
signal
Displayed item
D-IN-32
D-IN-33
D-IN-34
High beam (Dimmer switch)
High beam = ON (GND)/OFF (OPEN)
D-IN-35
Omission of applying parking brake

(dummy)
D-IN-36
Parking brake (dummy)
D-IN-37
[>] switch
Pressing switch = ON (GND)/OFF (OPEN)
D-IN-38
[<] switch
D-IN-39
Low steering pressure (Machine with

optional emergency steering spec.)
Oil pressure reduction = ON (GND)/OFF (OPEN)
D-OUT-0
Alarm buzzer
Output ON = ON (24 V)/OFF (OPEN)
D-OUT-1
D-OUT-2
Backup alarm/lamp relay
D-OUT-3
ECSS solenoid relay

(Machine with optional ECSS spec.)
*: 1 is displayed when ON and 0 is displayed when OFF.
30-130
33

SEN03936-01
a

HST [HST controller system]
No.
Monitoring
code
20201
Software No.
VERSION
20223
Application version No.
VERSION (APP)
20224
Data version No.
VERSION (DATA)
40977
D-IN--0------7
See separate table.
40978
D-OUT-0------7
See separate table.
40979
D-OUT-8-----15
See separate table.
40980
D-OUT-16----23
See separate table.
41600
Engine mode
ENGINE MODE
0/2
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
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
30-130
34
Real-time monitoring item

(*1)
Displayed item
(*2)
Data display range

(*3)
0/2/1
0/1

SEN03936-01

Unit
(*4)
As per software No.
Condition display
As per software application version No.
Condition display
As per software data version
Condition display
Remarks
Condition display
Condition display
Condition display
Condition display
0
Low-pressure relief pressure: 2.5 2.8
High-pressure cutoff pressure: 43.1 46.6
Low-pressure relief pressure: 0.667 0.687
High-pressure cutoff pressure: 3.373 3.607
Condition display 0 is always displayed.

MPa
V
Above 10.5 km/h in 3rd or 4th gear speed: 0 mA

Other than above: 100 600 mA (Depends on control)
mA
When clutch is engaged: 670 mA

When clutch is disengaged (Above 10.5 km/h in 3rd or
4th gear speed): 0 mA
mA
0 1000 mA
Fan rotation direction is being reversed: 800 mA
Fan is rotating in reverse: 0 mA
mA
Switch position, forward: 0

Switch position, automatic reverse: 2
Manual reverse switch is being operated: 1
Condition display
Depends on travel speed.
km/h
Not used
0 km/h = 0 min-1
10 km/h = 754 min-1
20 km/h = 1509 min-1
30 km/h = 2264 min-1
40 km/h = 3019 min-1
min-1
min-1 is SI unit of rotation speed.

(1 min-1 = 1 rpm)
0%
Ordinary: 100%
Forward travel in S mode: 50 100%
0%
Directional lever in N, stopped: 0 (OFF)

Other than above: 1 (ON)
0% is always displayed.
0% is always displayed.
Condition display
30-130
35

SEN03936-01
a

No.
Monitoring
code
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
30-130
36
Real-time monitoring item

(*1)
Displayed item
(*2)
Data display range

(*3)
F/R

SEN03936-01

Parking brake position (High): 00

(Middle): 10
(Low): 11
0 30 V
Unit
(*4)
Remarks
Condition display
4.0 13.0 km/h (Depends on travel speed control dial

position)
km/h
0.9 4.1 V (Depends on travel speed control dial position)
Traction level setting (When stopped)

When traction level A is set: 84%
When traction level B is set: 74%
When traction level C is set: 64%
100: F, 010: N, 001: R

ON/OFF refers to each bit.
Condition display
Stopped: 0
Forward travel (Directional lever in F): 1
Reverse travel (Directional lever in R): 2
Forward travel, lever in R: 3
Reverse travel, lever in F: 4
Forward travel, lever in N: 5
Reverse travel, lever in N: 6
Condition display
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
(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
Condition display
Forward travel: F
Reverse travel: R
Condition display
Display is as shown at left, regardless of traction control

switch position.
Previous condition is displayed while machine is

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.
30-130
37

SEN03936-01

No.
Monitoring
codes
Input/Output
signal
Displayed item
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)
D-IN-3
Right FNR (directional) switch selector

switch
D-IN-4
Traction control switch
D-IN-5
D-IN-6
D-IN-7
D-OUT-0
D-OUT-1
D-OUT-2
D-OUT-3
D-OUT-4
D-OUT-5
D-OUT-6
D-OUT-7
D-OUT-8
D-OUT-9
D-OUT-10
D-OUT-11
D-OUT-12
D-OUT-13
40977
40978
40979
D-OUT-14
VIS Self-holding relay
Output ON = ON (GND)/OFF (OPEN)
D-OUT-15
HST safety relay
D-OUT-16
Motor 2 solenoid relay
D-OUT-17
Fan reverse solenoid relay
D-OUT-18
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)
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

SEN03936-01
ENG [Engine controller system]

No.
Monitoring
code
Monitoring items
(*1)
Displayed items
(*2)
20400
Hardware serial No.
03200
Battery voltage
POWER SUPPLY
01002
Engine speed
ENG SPEED
ECM S/N
Data display range

(*3)
Unit
(*4)
Arabic numerals
Status
display
0.0 480.0
0 4000
rpm
04104
Engine coolant temperature
COOLANT TEMP
40 210
04105
Engine coolant temperature sensor voltage
COOLANT TEMP
0.00 5.00
36400
RAIL PRESS
0 400
MPa
36402
Common rail pressure sensor voltage
RAIL PRESS
0.00 5.00
37400
Atmospheric pressure
AMBIENT PRESS
99.9 999.9
kPa
37402
Atmospheric pressure sensor voltage
AMBIENT PRESS
0.00 5.00
10
18500
Boost temperature
CHG TEMP
50 200
11
18501
Boost temperature sensor voltage
CHG TEMP
0.00 5.00
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
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
17
37300
Momentary fuel consumption
FUEL RATE
18
18600
Final injection volume command (in weight)
INJECT COMMAND
19
36300
Final injection timing command TFIN
INJECT TIMING
20
31701
Accelerator pedal position
21
31707
Accelerator pedal sensor voltage
22
18300
23
18301
24
0 100
0.0 999.9
1/h
Remarks
0 1000
mg
180.0 180.0
CA
THROTTLE POS
0 100
THROTTLE POS
0.00 5.00
IVS 1
ON/OFF
Status
display
IVS 2
ON/OFF
Status
display
18900
Engine controller internal temperature
ECM IN TEMP
40 210
25
36200
Final common rail pressure command

PFIN
PRESS COMMAND
0 400
MPa
26
17500
Selection of engine mode
POWER MODE
04
Status
display
27
18800
WIF sensor stats
WATER IN FUEL
ON/OFF
Status
display
MACHINE ID (H)
Incoming value is
displayed as is
(Upper 8 digits of
16 characters)
Status
display
Status
display
28
00400
Name of selected model (upper 8 digits)
29
00401
Name of selected model (lower 8 digits)
MACHINE ID (L)
Incoming value is
displayed as is
(Lower 8 digits of
16 characters)
30
20216
Build version
BUILD VER
Incoming value is
displayed as is
(8 characters)
Status
display
31
20217
Calibration data version
CAL VER
Incoming value is
displayed as is
(8 characters)
Status
display
*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.
30-130
39

SEN03936-01
5.
Engine reduced-cylinder function (CYLINDER CUT-OUT)

The engine reduced-cylinder function denotes
setting the injector of a single cylinder or two or
more cylinders to electrically no injection state
and turns on the operation on reduced-cylinder
condition. When any cylinders of the engine
were suspected for abnormal output (combustion), this approach is used to single out the
failed cylinder.
1) Selecting the menu
Display the CYLINDER CUT-OUT screen
from the menu screen of Service mode.
2)
3)
a
a
Displaying sub menu

Press [U] switch while the menu i s
selected to display the sub menu.
a
30-130
Selecting a cylinder to be reduced

Using [<] or [>] switch, select a cylinder to
be reduced from No. 1 No. 6 cylinders
and then settle the selected cylinder using
[U] switch.
The cylinder to be reduced is selectable
while the engine is run.
Any number of cylinders can be reduced
a single unit or two or more units.
q
[>] switch: Advances the cursor rightward
q
[<] switch: Advances the cursor leftward
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
40
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.

4)
Cancelling a reduced cylinder

Using [<] or [>] switch, select the currently
stopped cylinder and then press [U]
switch to cancel the reduced-cylinder
command from the engine controller. The
black display will disappear.
SEN03936-01
2)
a
a
6.

The machine monitor is equipped with the
function capable of lubricating the engine
through no injection cranking. When a machine
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
Pressing [U] switch sets up the no injection cranking.

If this screen does not appear as [U]
switch is hit, a communication error should
be suspected.
If the no injection cranking is selected as

the engine is running, the engine stop
instruction screen will appear.
In such case, stop the engine once and
then do the set up again.
30-130
41

SEN03936-01
7.
Adjustment function (TUNING)

The machine monitor implements initial setting
after disassembly or replacement of the transfer, or after replacement or addition of sensor,
HST pump, HST motor and EPC valve or controller. Through the initial setting, the machine
monitor corrects and adjusts the installation
error or manufacturing variations of individual
parts.
a Adjustment function
Item Code
No. No.
Adjustment item
7-1
03
Adjustment of interval of fan automatic reverse operation
7-2
04
Adjustment of continuance of fan

automatic reverse operation
7-3
05
Adjustment of lift arm angle sensor

(upper) (for load meter) (*)
7-4
06
Adjustment of lift arm angle sensor

(lower) (for load meter) (*)
7-5
07
Adjustment of ECSS operation travel

speed
7-1. Adjustment of interval of fan automatic

reverse operation
a This function is used to change the interval of the forward and reverse operations
of the fan when the fan automatic reverse
operation is selected.
a The interval of the fan automatic reverse
operation is adjustable in the range from
0.1 h (6 minutes) to 200 h. It must be set
to at least twice the continuance of the fan
automatic reverse operation, however,
and cannot be set shorter than twice.
a When the machine is delivered, the interval of fan automatic reverse operation is
set to 2.0 h.
a When the machine is delivered, the continuance of the fan automatic reverse
operation is set to 2 minutes.
1) On the service mode menu screen, display the TUNING screen.
* This menu is displayed but it is not used.
The items which prohibit use

The setting of following items (code: 01,
02) are not changed because of prohibition of use.
2)
30-130
42
Hold down the [U] switch for at least 5

seconds to display the next screen.
a Do not use this item.

3)
With the [<] and [>] switches, select 03:

FAN REV PD screen.
4)
Press the [U] switch to settle.

a If the [U] switch is pressed, the screen
to adjust the interval of fan automatic
reverse operation is displayed.
With the [<] and [>] switches, select an
interval in the range from 0.1 to 200
(Unit: h).
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.
5)
6)
SEN03936-01
7-2. Adjustment of continuance of fan automatic
reverse operation
a This function is used to change the continuance 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, however, and cannot be set longer than 1/2.
a When the machine is delivered, the continuance of fan automatic reverse operation is set to 2.0 minutes.
a When the machine is delivered, the interval of the fan automatic reverse operation
is set to 2.0 h.
1) On the service mode menu screen, display the TUNING screen.
2)

30-130
43

SEN03936-01
3)
With the [<] and [>] switches, select 04:

FAN REV PD screen.
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.
With the [<] and [>] switches, select a continuance in the range from 0.5 to 10
(Unit: minute).
Press the [t] switch to settle the setting.
a The selected continuance of fan automatic reverse operation is not
changed to a value longer than 1/2 of
the interval of the fan automatic
reverse operation.
5)
6)
7-5. Adjustment of ECSS operation travel speed

(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 (3.1 MPH).
a The ECSS reset travel speed is the ECSS
operation travel speed minus 1 km/h (0.6
MPH).
Example: q If the ECSS operation travel
speed is 5 km/h (3.1 MPH),
the ECSS reset travel speed
is 4 km/h (2.5 MPH).
q If the ECSS operation travel
speed is 8 km/h (5.0 MPH),
the ECSS reset travel speed
is 7 km/h (4.4 MPH).
1) Display the TUNING screen from the
2)

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

3)
Select 07: ECSS SPEED with [<] or [>]

switch.
4)
Press [U] switch to settle.

a If the selection is settled, the ECSS
operation travel speed adjustment
screen appears.
SEN03936-01
8.

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
timer for items
8-1. Changing maintenance interval time
1) Display the MAINTENANCE MONITOR
screen from the menu screen of Service
mode.
2)
a
a
5)
6)
7)
To increase the ECSS operation travel

speed, press [>] switch.
a The operation travel speed is
increased 1 km/h (0.6 MPH) by 1
operation of the switch.
a The operation travel speed can be
adjusted to a maximum of 8 km/h (5.0
MPH).
To decrease the ECSS operation travel
speed, press [<] switch.
a The operation travel speed is
decreased 1 km/h (0.6 MPH) by 1
operation of the switch.
a The operation travel speed can be
adjusted to a minimum of 5 km/h (3.1
MPH).
If the operation travel speed is set to a
desired value, press [t] switch to finish
setting.
3)
Press [U] switch to display 01: ENG OIL

screen.
The lower left side space indicates the
time remained up to the replacement.
The lower right side space indicates the
cumulative replacement frequencies.
Using [<] or [>] switch, select the item for
which the maintenance interval is to be
changed from the following.
30-130
45

SEN03936-01
List of maintenance items
Item
ID No.
Indication of items on the

character display
Replacement
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

by use of [U] switch.
5)
Maintenance interval time change procedure

1] This cursor is located at the highestorder digit. Pressing [<] or [>] switch
changes the value of this digit in the
range of 0 9.
2] Press [U] switch when the intended
value.
a The cursor moves to the 2nd digit.
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 current value and the input screen will be
restored.
The shortest interval time value is 50 h.
30-130
46
When you have entered a wrong value to

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.

6)
a
a
a

switch.
Y ES i s s ele cted and [t] s witc h i s
maintenance interval change item screen
is restored.
When an interval time is changed, the
timer remaining time is changed as shown
below.
Timer remaining time = Interval time being
set Elapsed time from the last replacement
8-2. Selection between enabling or disabling timer

by item
1) Pressing [<] or [>] switch from 8-1-3) Interval time change screen displays the
timer by item screen.
a When Timer by item is enabled, the
order of display is ON o OFF.
SEN03936-01
a
a
When Timer by item is disabled, the

order of display becomes OFF o ON.
The default display is ON.
2)
a
Press [U] switch from this state.

If Timer by item is disabled, OFF will be
displayed in the upper column.
If Timer by item is enabled, ON will be

displayed in the upper column.
30-130
47

SEN03936-01
3)
a
a
a

switch.
Y ES i s s ele cted and [t] switc h i s
is restored.
An interval time is changed, the timer
remaining time is changed as shown
below.
Timer remaining time = Interval time being
set Elapsed time from the last replacement
3)
4)
a
Press [U] switch from this state.

Select YES or NO using [<] or [>] switch.
YE S is s elec ted a nd [ t] s witc h is
pressed, the change will be enabled If
pressed, the change will not be implemented and the maintenance monitoring
screen will be restored.
8-3. Changing set default value.

1) Press [U] switch from the MAINTENANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
a
a
2)
Using [<] or [>] switch, select the INITIALIZE

screen from the following table.
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.
Timer remaining time shall be Default
value E lapsed time s ince the l ast
replacement.
Executing the default value setting does
not affect the reset frequency. Namely, it
remains the same as before this operation
was executed.
Set enable for enable or disable of individual items.
8-4. Selection between timer stop for all items and

enable by item
1) Press [U] switch from the MAINTENANCE MONITOR screen of Service
mode to display 01: ENG OIL screen.
30-130
48

2)
3)
Using [<] or [>] switch, select the ALL

ITEMS OFF OR ON screen from the following table.
SEN03936-01
5)
a
Press [U] switch to display the ALL

ITEMS o OFF screen.
a
6)
a
a
4)
Press [U] switch from the ALL ITEMS o

OFF screen or the ALL ITEMS o ON
screen.
When [U] switch is pressed from the ALL
ITEMS o OFF screen, OFF will be is displayed in the upper space.
Press [<] or [>] switch when selecting the

ALL ITEMS o ON.
When [U] switch is pressed from the ALL

ITEMS o ON screen, ON will be is displayed in the upper space.
switch.
YE S is s elec ted a nd [t] s witc h is
is restored.
30-130
49

SEN03936-01
7)
a
a
a
8)
a
a
a
a
a
9.
As the timer stop for all items is executed:

The timer function for all items is stopped
a n d t h e M A I N TE N A N CE M O NI TO R
screen is restored.
Setting for individual items is also disabled.
If cancelled: The operation is cancelled
screen is restored.
When timer enable for all items is executed:
Interval time being set for all items is executed to the set value before disabled
i nd e p e nd e n t o f wh e th e r o r n ot i t i s
enabled or disabled for a specific item.
The timer remaining time is reset. (The
reset frequency remains the same as
before the resetting.)
The MAINTENANCE MONITOR screen is
restored.
Setting for individual items is also enabled.
If cancelled: The operation is cancelled
screen is restored.

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
1) Selecting menu
Display the OPERATION INFO screen
3)
Using [<] or [>] switch, select the item to

be displayed from 1] 4] on the fuel consumption ratio and average fuel consumption screen.
1] Fuel consumption ratio and average
fuel consumption screen
a The upper column displays fuel consumption [L/km or L/mile] per 1 km (or
1 mile) from the last resetting.
q
Above value is computed from the
fuel consumption ratio and travel distance (odometer distance).
a The lower column displays the average fuel consumption [L/h] from the
last resetting.
a Calculation is done only for the duration in which the engine is run.
2]
a
2)
30-130
Cumulative fuel consumption and travel

distance
The upper column displays the cumulative fuel consumption [L] from the
last resetting.
The counting is stopped at 99999.9,
the upper limit.
The lower column displays the travel
distance [km or mile] from the last
resetting.
The unit km or mile shall be selected
depending on that used on the odometer.
the upper limit.
Calculation is done only for the duration in which the engine is run.
Press [U] switch to display the fuel consumption ratio and average fuel consumption screen.
50

SEN03936-01
4)
a
a
a
3]
a
Cumulative fuel consumption and

elapsed time
The upper column displays the cumulative fuel consumption [L] from the
last resetting.
the upper limit.
The lower column displays the
elapsed time [h] from the last resetting.
the upper limit.
Calculation is done only for the duration in which the engine is run.
5)
a
a
Deleting display data

Data on screens 3) 1] to 3] allow deletion.
Select a desired item and then delete it
using [U] switch.
Use [t] switch when canceling deletion of
data.
Setting gain correction

Gain correction denotes the function of
correcting gain to cumulative fuel consumption.
Gain correction is reflected 3) 1] to 3].
1] After deleting data (RESET screen),
press [<] or [>] switch to display the
current set value.
2]
a
a
3]
4]
5]
a
6]
Pressing [U] switch displays the correction screen.

Default value: 0.0%
This setting allows correcting the
cumulative fuel consumption in the
range of 50.0 to +50.0.
Move the cursor to [+] or [].
Pressing [<] or [>] switch alternately
displays [+] and [].
Press [U] switch to settle [+] or [].
The cursor moves to the highestorder digit of the set value.
Pressing [<] or [>] switch changes the
value of this digit in the range of 0 9.
30-130
51
SEN03936-01
7]
a
8]
a
a
30-130
52

Press [U] switch when the intended

value.
The cursor moves to the 2nd digit.
Set the values up to the lowest digit in
the same order as above and then
press [U] switch to settle.
As the selection is settled, the preceding screen is restored.
If [t] switch is pressed before finishing entering, the cursor moves to the
[+] and [] position. In this case, the
value remains unchanged. Pressing
[t] switch again restores the preceding screen.
If the value is not in the 50 +50
range, pressing [U] switch at the lowest digit just moves the cursor the [+]
and [] position and the value
remains as it is.

SEN03936-01
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
No.
Item
Display in
English
Setting at monitor delivery

Contents of selection
For SI
For non-SI
Tire type
TIRE TYPE
20.5
20.5
Emergency steering
EMERG S/T
NO ADD
NO ADD
If equipped, select ADD.
Right FNR (directional)

switch
FNR
NO ADD
NO ADD
If equipped, select ADD.
Keep 20.5
ECO lamp operation
ECO LAMP
ADD
ADD
Keep to ADD normally.

NO ADD is selected, ECO
lamp in machine monitor is
kept turned OFF.
ECSS
E. C. S. S.
ADD
ADD
If not installed optionally, select

NO ADD.
Reverse fan
REVERSE FAN
ADD
ADD
If fan reverse function is not

installed, select NO ADD.
Parking brake
PKG BRAKE
MECHA
MECHA
Tire size correction
11 Travel speed unit
Selection of travel
12 speed/engine speed display on main screen
Selection of engine
speed/travel speed on
13 normal screen of character display or non-display
TIRE SIZE
SPEED (UNIT)
RPM OPT
RPM/SPEED
0%
(*1)
ADD
0%
MPH
NO ADD
ADD
Remarks
If electric parking brake is installed, MECHA: Mechanical

select ELEC.
ELEC: Electric
Keep to 0 normally.
If number other than 0 is
selected, only travel speed
display in machine monitor
increases or decreases
according to selected number.
Can be changed in only nonMPH: Display in mile
SI specification. For contents
km/h: Display in kilomeof change, see Remarks colter
umn.
Can be changed in only nonSI specification. For contents
of change, see Remarks column.
To change travel speed display to engine speed display
in operator mode, select
ADD.
Note: Do not select ADD in
region where display of travel
speed is obliged by law.
NO ADD: (*2)
ADD: (*3)
ADD o NO ADD: (*4)
NO ADD o ADD: (*5)
Keep to ADD normally.

If NO ADD is selected,
Engine speed or travel
speed are not displayed on
character display.
ADD: (*6)
NO ADD: (*7)
ADD o NO ADD: (*8)
NO ADD o ADD: (*9)
Reference: Item Nos. 8 and 10 are missing.

*1: Fixed to NO ADD (km/h) internally, although not displayed.
*2: Selection of speed/engine speed is not displayed in operator mode.
*3: Selection of speed/engine speed is displayed in operator mode (Tachometer can be displayed as main
item).
30-130
53
SEN03936-01
*4:
*5:
*6:
*7:
*8:
*9:

Fixed to speedometer.
Setting at previous ADD or initial setting.
Travel speed/rpm on character display: Displayed/Not displayed is displayed in operator mode.
Travel speed/rpm on character display: Displayed/Not displayed is not displayed in operator mode.
Not displayed.
Setting at previous ADD or initial setting.
30-130
54

1)
Display the OPTIONAL SELECT screen

2)
Hold down [U] switch for 5 seconds or

longer.
The 1: TIRE TYPE screen will appear.
a If the [t] switch is pressed, the
screen returns to the OPTIONAL
SELECT screen.
3)
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
changing or settling the option, set
other items in order on the next 2:
EMERG S/T screen and the following
screens.
SEN03936-01
10-1. Option setting/not setting selection
a Among the items included in the list of installed
optional devices and their setting, the option
setting/not setting selection applies to the following items.
a If the options are not selected, the option nonselection screen (NO ADD) is displayed.
If the options are selected, the option selected

screen (ADD) is displayed.
[U] switch allows alternately displaying the

option non-selection screen and the optionselected screen.
Reference: Details of the main items are shown

below.
30-130
55

SEN03936-01
10-2. Selection of optional tire type
a Select 1: TIRE TYPE from Optional device
installation setting table.
Reference: This screen appears first when the
screen is changed from the OPTIONAL
SELECT screen.
a Each time [U] switch is pressed, the tire type
changes from small to large.
Selectable size: 20.5
a Select only 20.5 (Do not change)
a If the tire type is changed, the operation acceptance tone (peep) sounds.
10-4. Setting tire deflection option

a Select 9: TIRE SIZE from the list of installed
optional devices and their setting.
a Pressing [U] switch sequentially displays
[@@]% in the following order.
a The display progresses from +00 through 10.
Pressing [U] switch at this point returns the
display to +00.
Order No.1
No.2
No.3
No.4
No.5
No.6
No.7
@@
+02
+04
+06
+08
+10
+12
+00
Order No.8
@@
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)
a If the parking brake type is changed, the operation acceptance tone (peep) sounds.
30-130
56
02
No.9 No.10 No.11 No.12 No.13 No.14

4
10
12
+00
As the display is switched, the sound (beep)

indicating acceptance of the operation will be
generated.
10-5. Selection of optional travel speed unit

a If the SI unit specification is selected when
delivered, this menu is not displayed. (Unit is
fixed to km/h.)
a Select 11: SPEED UNIT from Optional
device installation setting table.
a Each time [U] switch is pressed, the speed
unit changes.
Selectable item: MPH (default), km/h
a If the unit is changed, the operation acceptance tone (peep) sounds.

10-6. Storing option selection

1) When the option selection was changed,
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 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.
SEN03936-01
11. Machine serial number input function
1) Display the MACHINE No. SET screen
2)
3)
Press [U] switch to display the MACHINE

No. screen.
Enter the serial number according to the
a The cursor is positioned at the highest-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 selection.
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
press [U] switch to settle.
a As the selection is settled, the immediately preceding screen is restored.
a Pressing [t] switch while entry is taking
place will move the cursor the highestorder digit. In this case, repeat entry
from the highest-order digit.
a If [t] switch is pressed while the cursor is at the highest-order digit, the
immediately preceding screen will be
restored.
30-130
57

SEN03936-01
12. Machine model select function
(MACHINE WA***)
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, perform 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.
3)
12-1. Implementing the model change

1) Display the MACHINE screen from the
a The currently selected machine model is
displayed on the lower line.
4)
a
2)
Hold down [U] switch for 5 seconds to

display the model selection screen.
With the [<] and [>] switches, select the

machine model.
a Selectable models
q
WA100
q
WA150
q
WA200
q
WA250
q
WA270
q
WA320
a If wrong model and tire are set,
machine does not work correctly.
Press [t] switch when stopping the model
selection.
As the operation is stopped, the sound
(beep) indicating acceptance of the operation will be generated, restoring the
MACHINE screen.
With the [U] switch, settle the changed
machine model and tire size.
As the selection is settled, the sound
(beep) indicating acceptance of the operation will be generated, restoring the
MACHINE screen.
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.
30-130
58

SEN03936-01
14. Item that refers to SERVICE NEWS

Refer to SERVICE NEWS for the following
items.
q
Setting of service meter when machine
monitor is exchanged.
q
Setting of odometer when machine monitor is exchanged.
30-130
59

Pm clinic inspection chart
SEN03936-01
WA320-6 Serial No. 70001 and up
Machine serial No.

Hours inspection
Work order No.
Engine serial No.
Date of execution
Year:
Month:
SAA6D107E-1 #
Service Meter
Serviceman
Day:
Questions asked to operator, walk around inspection

Ambient temperature
Max.
C
Was there any abnormality before inspection started?
Max. coolant temp. (During operation)

Segment color
W G G G G R R
1 2 3 4 5 6 7
Segment color
Conditions
Unit
High idle
Engine speed
Engine
G G G G G R R
1 2 3 4 5 6 7
rpm
HST stall
800 850
800 850
Measurement
results
Pass
Fail
2,110 2,310 2,010 2,300
1,830 2,160 1,730 2,260

kPa
{mmH2O}
At rated output
High idle
Oil pressure
Service limit
value
2,050 2,250 1,950 2,300
Full stall (HST stall + hydraulic stall)

Blow-by
pressure
Standard
value for new
machine
2,200 2,300 2,200 2,300
Hydraulic stall
SAE15W-40
Low idle
HST
Max. HST oil temp. (During operation)
Low idle
Altitude
If the machine is cold, warm it up fully. <>: Reference value

Item
Min.
MPa
{kg/cm2}
Max. 0.98
{Max. 100}
1.96
{200}
Min. 0.29
{Min. 3.0}
0.25
{2.5}
Min. 0.10
{Min. 1.0}
0.07
{0.7}
Before starting the inspection, check that the machine does not move when the directional lever is placed in position.
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.
High-pressure
cut-off pressure
Directional lever: F
Speed selector
switch: 2nd
Traction control
switch: ON
42.9 45.3
{438 462}
41.1 45.3
{420 460}
Low-pressure
relief pressure
(work equipment PPC circuit basic
pressure)
3.0 3.2
{31 33}
2.9 3.2
{30 33}
Engine:
Full throttle
Hydraulic
Brake: released
oil temp.:
45 55C Directional lever: N
Brake: pressed
3.0 3.2
{31 33}
2.9 3.2
{30 33}
Max. 0.6
{Max. 6}
Max. 0.6
{Max. 6}
Directional lever: Forward and reverse

Gear speed selector
switch: 1st
Travel speed control
dial: Min. side
Measure while driving at full throttle
(Approx. 5 km/h).
3.0 3.2
{31 33}
2.8 3.2
{29 33}
Directional lever: F
Speed selector
switch: 3rd or 4th
3.0 3.2
{31 33}
2.9 3.2
{30 33}
Servo piston
control pressure
Servo piston
actuation pressure
Transfer clutch
control pressure
30-130
60
Hydraulic oil
temp.:
45 55C
MPa
{kg/cm2}

SEN03936-01
WA320-6 Serial No. 70001 and up
<>: Reference value
Steering
Item
Steering wheel
operating time
Conditions
Engine low idle
Unit
sec.
Engine high idle
Steering relief
pressure
MPa
{kg/cm2}
Engine high idle
Brake
Service brake
Lining thickness
Front left
Rear right
mm
Rear left
Relief pressure
Work equipment
Service limit
value
3.3 4.1
Max. 4.8
3.4 4.0
2.7 4.7
20.1 21.6
{205 220}
18.6 22.6
{190 230}
0.9 1.1
Max. 0.6
0.9 1.1
Max. 0.6
0.9 1.1
Max. 0.6
Measurement
results
Pass
Fail
Lock frame with frame lock bar
Front right
Lift arm speed
0.9 1.1
Max. 0.6
20.2 21.0
{206 214}
18.6 22.6
{190 230}
Raising time
5.2 6.2
Max. 8.6
Lowering time
3.0 4.0
Max. 5.3
0.9 1.5
Max. 1.8
0.9 1.5
Max. 2.0
Bucket relief
Engine high
idle
Dumping time
Bucket speed
Hydraulic drift
Axle
Standard
value for new
machine
MPa
{kg/cm2}
sec.
Tilting-back time
(At full stroke)
Engine
stopped
Check differential oil visually
Bucket cylinder
Lift cylinder
Front axle
Rear axle
mm/15
min.
Max. 17
Max. 26
Max. 20
Max. 30
Must be no excessive metal

particles
MEMO
30-130
61
SEN03936-01

2009 KOMATSU
All Rights Reserved
30-130
62
SEN03937-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
40 Troubleshooting
40

Failure codes table.......................................................................................................................................... 2
Fuse locations................................................................................................................................................. 8
40-100

Failure codes table
SEN03937-01
Failure codes table

Failure
code
Troubled part
Trouble
Controller
Action
code
Category of
Reference
record
document No.
2G40ZG Brake
MON
E03
Mechanical
system
6091NX
HST filter
Clogging
MON
E01
Mechanical
system
989FN1
Travel speed
Overrun alarm
MON
E02
Mechanical
system
AA1ANX Air cleaner
Clogging
MON
E01
Mechanical
system
AB00L6
Hot short
MON
E01
Electrical
system
AB00MA Alternator R system
Ground fault/Disconnection/Low charge level
MON
E03
B@BAZG Engine
ENG
E03
B@BAZK Engine oil
Low oil level
MON
E01
B@BCNS Engine
Overheat
ENG
E02
Mechanical
system
B@BCZK Engine
Low coolant level
MON
E01
Mechanical
system
B@C6NS Front brake
MON
E02
Mechanical
system
B@CRNS HST
MON
E02
Mechanical
system
Alternator R system
Troubleshooting by failure
code (Display
Mechanical of code), Part 1
system
SEN03939-00
Mechanical
system
Electrical
system
CA111
Engine controller
Internal abnormality
ENG
E03
Electrical
system
CA115
Engine NE, Bkup speed

sensor
Abnormality
ENG
E03
Electrical
system
CA122
ENG
E03
Electrical
system
CA123
ENG
E03
Electrical
system
CA131
Throttle sensor
ENG
E03
Electrical
system
CA132
Throttle sensor
ENG
E03
Electrical
system
CA144
Coolant temperature sensor Abnormally high level
ENG
E01
Electrical
system
CA145
Coolant temperature sensor Abnormally low level
ENG
E01
Electrical
system
CA153
Charge temperature sensor Abnormally high level
ENG
E01
Electrical
system
CA154
Charge temperature sensor Abnormally low level
ENG
E01
Electrical
system
CA155
Charge temperature
Abnormally high speed

derate
ENG
E03
Electrical
system
CA187
ENG
E03
Electrical
system
CA221
ENG
E01
Electrical
system
40-100
code (Display
of code), Part 2
SEN03940-00

Failure codes table
Failure
code
Troubled part
SEN03937-01
Trouble
Controller
Action
code
Category of
Reference
record
document No.
CA222
ENG
E01
Electrical
system
CA227
ENG
E03
Electrical
system
CA234
Engine
Overspeed
ENG
E02
Mechanical
system
CA238
Ne speed sensor power

supply
Abnormality
ENG
E03
Electrical
system
CA271
IMV (IMA)
Short circuit
ENG
E03
Electrical
system
CA272
IMV (IMA)
Disconnection
ENG
E03
Electrical
system
CA322
Injector #1 system
ENG
E03
Electrical
system
CA323
Injector #5 system
ENG
E03
Electrical
system
CA324
Injector #3 system
ENG
E03
Electrical
system
CA325
Injector #6 system
ENG
E03
Electrical
system
CA331
Injector #2 system
ENG
E03
Electrical
system
CA332
Injector #4 system
ENG
E03
Electrical
system
CA342
Engine controller
Data mismatching
ENG
E03
Electrical
system
CA351
Injector drive circuit
Abnormality
ENG
E03
Electrical
system
CA352
ENG
E03
Electrical
system
CA386
ENG
E03
Electrical
system
CA428
Water sensor
ENG
E01
Electrical
system
CA429
Water sensor
ENG
E01
Electrical
system
CA431
Abnormality
ENG
E01
Electrical
system
CA432
Abnormal remedy
ENG
E03
Electrical
system
CA435
Engine oil pressure switch
Abnormality
ENG
E01
Electrical
system
CA441
ENG
E03
Electrical
system
CA442
ENG
E03
Electrical
system
CA449
Abnormally high pressure

2
ENG
E03
Electrical
system
CA451
Common rail pressure senAbnormally high level

sor
ENG
E03
Electrical
system
code (Display
of code), Part 2
SEN03940-00
code (Display
of code), Part 3
SEN03941-01
40-100

Failure codes table
SEN03937-01
Failure
code
Troubled part
Trouble
Controller
Action
code
Category of
Reference
record
document No.
ENG
E03
Electrical
system
CA452
Common rail pressure sensor Abnormally low level
CA488
Charge temperature
Abnormally high torque

derate
ENG
E03
Electrical
system
CA553
Abnormally high pressure

1
ENG
E03
Electrical
system
CA559
Supply pump
Low rail pressure 1
ENG
E03
Electrical
system
CA689
Engine Ne speed sensor
Abnormality
ENG
E03
Electrical
system
CA731
Engine Bkup speed sensor Abnormal phase
ENG
E03
Electrical
system
CA757
Engine controller
Loss of all data
ENG
E03
Electrical
system
CA778
Abnormality
ENG
E03
Electrical
system
CA1633
KOMNET
Abnormality
ENG
E03
Electrical
system
CA2185
Throttle sensor power supply Abnormally high level
ENG
E03
Electrical
system
CA2186
Throttle sensor power supply Abnormally low level
ENG
E03
Electrical
system
CA2249
Supply pump
Low rail pressure 2
ENG
E03
Electrical
system
CA2311
IMV (IMA) solenoid
Abnormality
ENG
E03
Electrical
system
CA2555
Disconnection
ENG
E01
Electrical
system
CA2556
Short circuit
ENG
E01
Electrical
system
D160KY
Backup lamp/buzzer relay
Hot short
MON
E01
Electrical
system
D192KY
ECSS solenoid relay
Hot short
MON
E01
Electrical
system
D1B0KA HST safety relay
Disconnection
HST
E03
Electrical
system
D1B0KB HST safety relay
Ground fault
HST
E01
Electrical
system
D1B0KY HST safety relay
Hot short
HST
E03
Electrical
system
D5ZHL6
MON
E01
Electrical
system
MON
E01
Electrical
system
Disconnection
HST
E03
Electrical
system
IGN C system
DAF3KK UNSW power supply

DAFRKR
Monitor panel CAN-NET

signal
DAJ0KK
HST controller power supply Low voltage
HST
E03
Electrical
system
DAJ0KT
HST controller memory

(EEPROM)
HST
E01
Electrical
system
40-100
Abnormality
code (Display
of code), Part 3
SEN03941-01
code (Display
of code), Part 4
SEN03942-01

Failure codes table
Failure
code
SEN03937-01
Troubled part
Trouble
Controller
Action
code
Category of
Reference
record
document No.
DAJ1L4
HST controller main power

line
Disconnection/Ground
fault
HST
E01
Electrical
system
DAJ1L6
HST controller main power

line
Hot short
HST
E01
Electrical
system
DAJ2KK
Controller solenoid power

supply
Low voltage
HST
E03
Electrical
system
DAJ2L3
HST controller load power

supply holding line
Hot short
HST
E01
Electrical
system
DAJ2L4
HST controller load power

supply holding line
fault
HST
E01
Electrical
system
DAJ5KX
Sensor 5V power supply
Out of input range
HST
E03
Electrical
system
(DAJ9KQ) HST controller
Disagreement in model
selection
MON
E03
DAJRKR HST controller CAN-NET
Disconnection in signal
line
MON
E03
Electrical
system
Disagreement in option
selection
MON
E03
Disconnection in signal
line
HST
E03
Electrical
system
HST
E01
Electrical
system
Abnormality
HST
E01
Electrical
system
(DAJRMA) HST controller

DB2RKR Engine controller CAN-NET
DD1NL4
Fan auto reverse switch sigAbnormality

nal
DD1NLD Fan reverse switch signal

DDB6KA

signal
HST
E01
Electrical
system
DDB6KB
Parking brake indicator

signal
Ground fault
HST
E01
Electrical
system
Trouble
MON
E03
Electrical
system
Ground fault
HST
E01
Electrical
system

DDB6KZ signal or parking brake
reminder signal
DDB6L0

signal
DDB6L4

signal
HST
E03
Electrical
system
DDD7KX Travel speed control dial
fault
HST
E01
Electrical
system
DDD7KY Travel speed control dial
Hot short
HST
E01
Electrical
system
MON
E01
Electrical
system
DDE5MA
Emergency steering operaDisconnection

tion switch
DDK3KA Right direction switch
HST
E03
Electrical
system
DDK3KB Right direction switch
Ground fault
HST
E03
Electrical
system
DDK6KA FNR lever
fault
HST
E03
Electrical
system
DDK6KY FNR lever
Hot short
HST
E03
Electrical
system
DDS5L6
Low oil pressure (Operation

of emergency steering)
MON
E03
Mechanical
system
Steering
code (Display
of code), Part 4
SEN03942-01
code (Display
of code), Part 5
SEN03943-01
40-100

Failure codes table
SEN03937-01
Failure
code
Troubled part
Trouble
Controller
Action
code
Category of
Reference
record
document No.
DF10KA
fault
HST
E01
Electrical
system
DF10KB
Hot short
HST
E01
Electrical
system
MON
E01
Electrical
system
DGH1KX HST oil temperature sensor Ground fault

DGR2KB
Ground fault
MON
E01
Electrical
system
DGR2KZ
MON
E01
Electrical
system
DHH1KX HST oil pressure sensor
fault
HST
E03
Electrical
system
DHH1KY HST oil pressure sensor
Hot short
HST
E03
Electrical
system
DHTCL6 HST filter clogging sensor
Functional defect
MON
E01
Electrical
system
DJF1KA
Fuel level sensor
MON
E01
Electrical
system
DLT3KX
Travel speed sensor B
Abnormality
HST
E03
Electrical
system
DLT4KX
Travel speed sensor A
Abnormality
HST
E03
Electrical
system
DLT4LC
Travel speed sensor A & B
Abnormality
HST
E03
Electrical
system
DV00KY Alarm buzzer
Hot short
MON
E01
Electrical
system
DW26KA Motor 2 solenoid
fault
HST
E01
Electrical
system
DW26KY Motor 2 solenoid
Hot short
HST
E01
Electrical
system
DW7BKY Fan reverse solenoid circuit Hot short
HST
E01
Electrical
system
DW7BKZ Fan reverse solenoid circuit
fault
HST
E01
Electrical
system
DX16KA Fan EPC solenoid
Disconnection
HST
E01
Electrical
system
DX16KB Fan EPC solenoid
Ground fault
HST
E01
Electrical
system
DX16KY Fan EPC solenoid
Hot short
HST
E01
Electrical
system
DX19KA Motor 1 solenoid
Disconnection
HST
E03
Electrical
system
DX19KB Motor 1 solenoid
Ground fault
HST
E03
Electrical
system
DX19KY Motor 1 solenoid
Hot short
HST
E03
Electrical
system
DX20KA Clutch EPC solenoid
Disconnection
HST
E03
Electrical
system
DX20KB Clutch EPC solenoid
Ground fault
HST
E03
Electrical
system
DX20KY Clutch EPC solenoid
Hot short
HST
E03
Electrical
system
40-100
code (Display
of code), Part 6
SEN03944-01
code (Display
of code), Part 7
SEN03945-00

Failure codes table
Failure
code
Troubled part
SEN03937-01
Trouble
Controller
Action
code
Category of
Reference
record
document No.
DXH7KB Reverse solenoid
Ground fault
HST
E03
Electrical
system
DXH7KZ Reverse solenoid
HST
E03
Electrical
system
DXH8KB Forward solenoid
Ground fault
HST
E03
Electrical
system
DXH8KZ Forward solenoid
HST
E03
J141N1
Steering pump
Overrun alarm
HST
E02
M100N1
HST pump
Overrun alarm
HST
E02
Mechanical
system
M400N1
Motor 1
Overrun alarm
HST
E02
Mechanical
system
a
a
a
Electrical
code (Display
system
of code), Part 7
Mechanical SEN03945-00
system
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.
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
Action codes:
Action codes indicate what is displayed in the operator mode when a failure is detected.
History classification:
History classification indicates in which system, either electrical system or mechanical system in the failure history display function, a failure has been recorded.
Note: Optional equipments are also included in the table.
40-100

Fuse locations
SEN03937-01
Fuse locations
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
Unswitched power supply

(Slow blow fuse [50 A])
Destination of power (*)
20A
Starting switch B
10 A
Hazard lamp
15 A
HST controller
30 A
Engine controller
10 A
Machine monitor
Tachograph
Buzzer
10 A
Radio
Auto-grease
Room lamp
10 A
Unswitched power supply for optional devices
10 A
Headlamp (left)
10 A
Headlamp (right)
10
10 A
Turn signal lamp
11
10 A
Stop lamp relay

Stop lamp switch
Stop lamp
12
15 A
VIS power supply holding relay

HST controller
13
10 A
Detent active relay

ECSS switch
Quick coupler
Boom kick-out relay
PPC solenoid
Bucket leveler relay
Proximity switch
14
20 A
Front/Rear wiper
Wiper timer
Window washer
15
10 A
Radio
Auto-grease
Cigarette lighter
Accessory power supply

(Slow blow fuse [80 A])
*: Optional devices are included.

Devices which are not set may be included.
40-100

Fuse locations
SEN03937-01
Fuse box: FS2

Fuse No. Fuse capacity
Accessory power supply

(Slow blow fuse [80A])
ACC signal (ACC switch)
Destination of power (*)
20 A
Air conditioner blower
5A
Air conditioner compressor
20 A
Beacon
Working lamp (Front: For addition)
Rotary lamp
20 A
Glass heater
10 A
Load meter, air cleaner clogging relay
20 A
Key ON power for optional device
10 A
DC converter
10 A
Parking brake
10 A
Horn
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)
14
10 A
Machine monitor (Starting switch ACC signal)

Backup lamp
Backup alarm
15
5A
Engine controller (Starting switch ACC signal)
*: Optional devices are included.

Devices which are not set may be included.
Location
q
Inside of cover (1) at rear of console in cab
Fuse No.
40-100

Fuse locations
SEN03937-01
Slow blow fuse
Accessory power supply (Battery)
Unswitched power supply (Battery)
Fuse capacity
80 A
Fuse box FS1 No.8 15

Fuse box FS2 No.1 15
120A
Engine intake air heater relay
50 A
Fuse box FS1 No.1 7
Location
Remove plate (2) on left side of engine compartment and remove cover (3).
40-100
10
Destination of power
Arrangement of slow blow fuse

Fuse locations
SEN03937-01
40-100
11
SEN03937-01

2009 KOMATSU
All Rights Reserved
40-100
12
SEN03938-02
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
40 Troubleshooting
40

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
40-200
SEN03938-02

k
k
k
k
k
k

Stop the machine in a level place, and check that the lock pin, blocks, and parking brake are
securely fitted.
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.
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.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air,
always 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 prevent reoccurrence of the failure. When carrying out troubleshooting, an important point is of course to understand 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 symptoms.
1.
2.
3.
4.
5.
6.
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
confidence 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.
Points to ask 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?
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.
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 investigation or measurement that may make the problem worse.
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.
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

Sequence of events in troubleshooting
SEN03938-02
Sequence of events in troubleshooting
(Rev. 2007.12)
40-200

Testing before troubleshooting
SEN03938-02
Testing before troubleshooting
Hydraulic and
mechanical equipment
Electrical parts
Lubricating oil and coolant
Item
Criteria
Remedy
1.
Check of level and type of fuel
Add fuel
2.
Check for foreign matter in fuel

Check fuel filter and fuel pre-filter for clogging
Clean or drain
3.
Check of fuel filter for clogging
Replace
4.
Check of level and type of oil in engine oil pan
Between H and L
Add oil
5.
Check of coolant level
Between FULL and

LOW
Add coolant
6.
Check of air cleaner for clogging
No red
Clean or replace
7.
Check of level and type of hydraulic oil
Between H and L
Add oil
8.
Check of level and type of HST oil
Between H and L
Add oil
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
13. Check of alternator terminal cables for looseness and

corrosion
14. Check of starting motor terminal cables for looseness and
corrosion
Retighten or
replace
Retighten or
replace
Retighten or
replace
15. Check of operation of instruments
Repair or replace
16. Check for abnormal noise and smell
Repair
17. Check for oil leakage
Repair
18. Bleeding air
Bleed air
19. Check of effect of brake
Repair or adjust
20 30 V
Charge or replace
Between U.L and L.L
Add or replace
22. Check wires for discoloration, burn, and removal of cover
Replace
23. Check for removed wire clamp and drooping wire
Repair
Disconnect and dry

connectors
Replace
After several-minute
operation: 27.5 29.5 V
Repair or replace
Replace
20. Check of battery voltage (with engine stopped)

21. Check of battery electrolyte level
Electrical equipment
24. Check wiring for wetting with water (Check connectors and
terminals for wetting with water, in particular)
25. Check of slow-blow fuses and fuses for disconnection and
corrosion
26. Check of alternator voltage (with engine at medium speed or
higher)
27. Check of operating sound of battery relay (Starting switch
OFF o ON)
40-200

Classification and procedures of troubleshooting
SEN03938-02
Classification of troubleshooting
Mode
Display of
code
Contents
Troubleshooting by failure code (Display of 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 troubleshooting 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 troubleshooting 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 troubleshooting related to that phenomenon in the E-mode, H-mode, or S-mode.
40-200

SEN03938-02
Phenomena looking like troubles and troubleshooting Nos.

Troubleshooting
No.
Phenomena looking like trouble
Code
display
E-mode
H-mode
S-mode
Phenomena related to action codes and failure codes

1 Action codes are displayed on machine monitor
2 If failure code display function is checked, failure codes are displayed
Check failure code

q
Phenomena related to engine

3 Engine does not start easily (Starting performance is poor)
Engine does not turn
4
5
Engine does not start
S-1
E-1
S-2 a)
Engine turns but no exhaust smoke comes out
S-2 b)
Exhaust smoke comes out but engine does not

start (Fuel is injected)
S-2 c)
7 Engine does not pick up smoothly
S-3
8 Engine stops during operation
H-4
9 Engine does not rotate smoothly
S-4
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)
24 The travel speed is high
E-3 c)
H-2
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

SEN03938-02
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
the air)
H-15
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
arm falls temporarily
H-18
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
47
The bucket wobbles during travel with load (The work equipment
valve is set to "HOLD")
H-24
48
When the control lever is switched from "HOLD" to "TILT," the bucket
falls temporarily
H-25
49
The control levers of the lift arm and bucket do not move smoothly
and heavy
H-26
50 The ECSS does not operate and machine pitches and bounces
E-4
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
H-27
Others
55
Fan revolution is abnormal (Fan sound/vibration is abnormally large

or engine overheats)
H-28
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
40-200

Information contained in troubleshooting table
SEN03938-02

Action code
Failure code
Monitor
display
Monitor display
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Action taken by machine monitor or controller to protect system or devices when engine controller detects trouble
Problem that appears on machine as result of action taken by machine monitor or controller
(shown above)
Information related to detected trouble or troubleshooting
40-200
Problem that appears on machine
State where the monitor panel or controller detects the trouble
Cause
Possible causes
and standard
value in normal
state
Trouble
Standard value in normal state/Remarks on troubleshooting

<Described contents>
Standard value in normal state to judge assumed cause
(good or not)
Remarks required to judge whether the cause is good
<Phenomenon of defective wiring harness>

Disconnection in wiring
The connector connection is defective or the wiring harness
is disconnected.
Grounding fault
A harness not connected to ground (earth) circuit comes
into contact with the ground (earth) circuit.
Hot short circuit
A harness not connected to the power (24 V) circuit comes
2
into contact with the power (24 V) circuit.
Short circuit
Possible causes of trouble
A harnesses of an independent circuit abnormally comes
is assumed to be detected
into contact with one of another circuit.
(The order number indicates
a serial number, not a priority <Notes on troubleshooting>
sequence.)
(1) Method of indicating connector number and handling Tbranch
For troubleshooting, insert or connect T-branch adapter
3
as shown below unless especially specified.
When male or female is not indicated for a connector number, disconnect the connector, and insert
the T-branch adapter in both the male and female.
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 ()
leads as shown below unless especially specified.
4
Connect the plus (+) lead to a pin or harness indicated in the front.
Connect the minus () lead to a pin or harness indicated in the rear.

SEN03938-02
Related circuit diagram
This is the excerpted circuit diagram related to trouble

Connector No.: Indicates (Model No. of pins) (Color)
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 harness.
Arrow (io): Roughly shows the location on the
machine.
40-200
SEN03938-02
Connection table for connector pin numbers

a

(Rev. 2009.04)
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

SEN03938-02
40-200
11
SEN03938-02
40-200
12


SEN03938-02
40-200
13
SEN03938-02
40-200
14


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15
SEN03938-02
40-200
16


SEN03938-02
40-200
17
SEN03938-02
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18


SEN03938-02
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19
SEN03938-02
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20


SEN03938-02
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21
SEN03938-02
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22


SEN03938-02
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23
SEN03938-02
40-200
24


SEN03938-02
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25
SEN03938-02
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26


SEN03938-02
40-200
27
SEN03938-02
40-200
28


SEN03938-02
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29
SEN03938-02
40-200
30


SEN03938-02
40-200
31
SEN03938-02
40-200
32


SEN03938-02
40-200
33
SEN03938-02
40-200
34


SEN03938-02
40-200
35
SEN03938-02
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36


SEN03938-02
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37
SEN03938-02
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38


SEN03938-02
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39
SEN03938-02
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40


SEN03938-02
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41
SEN03938-02
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42


SEN03938-02
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43
SEN03938-02
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44


SEN03938-02
40-200
45

T- branch box and T- branch adapter table
SEN03938-02
The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal
column indicates a part number of harness checker assembly.
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
Number of pins
(Rev. 2009.03)1
799-601-2600 T-box (for ECONO)
21
799-601-3100 T-box (for MS)
37
799-601-3200 T-box (for MS)
37
q
q
799-601-3380 Plate for MS (14-pin)

799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
24
MS-24P
17
MS-17P
17
MS-17P
MS-5P
10
MS-10P
MS-5P
17
MS-17P
19
MS-19P
14
MS-14P
MIC-5P
q q
13
MIC-13P
q q
17
MIC-17P
q q q
q q
21
MIC-21P
q q q
q q
MIC-9P
q q q
799-601-3470 Case
799-601-2750 Adapter for ECONO
ECONO2P
q q
ECONO3P
q q
ECONO4P
q q
ECONO8P
q q
12 ECONO12P q q
799-601-2810 Adapter for DLI
DLI-8P
q q
12
DLI-12P
q q
16
DLI-16P
q q
799-601-2840 Extension cable (ECONO type)
12 ECONO12P q q
799-601-4350 T-box (for DRC 60, ECONO)
799-601-2850 Case
60
799-601-4360 Case
q
X2P
q q q
X3P
q q q
X4P
q q q
SW6P
q q q
q q q
799-601-7010 Adapter for X (T-adapter)

SW8P
12
SW12P
14
SW14P
16
SW16P
799-601-7080 Adapter for M (T-adapter)
M2P
q q q
M3P
q q q
40-200
46
q
q
q
q

SEN03938-02
S8P
q q q
799-601-7150 Adapter for S (White)
10
S10P
q q q
799-601-7160 Adapter for S (Blue)
12
S12P
q q q
q q q
16
S16P
16
S16PW
12
S12PW
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-7170 Adapter for S (Blue)
799-601-9100
M8P
799-601-9000
799-601-8000
q
799-601-7500
q q q
799-601-7400
q q q
M6P
799-601-7100
M4P
799-601-7000
799-601-2800
Part name
799-601-2700
Identification
symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
q
q
q
A8P
12
A12P
16
A16P
q q q
20
A20P
q q q
799-601-7230 Short connector for X
q q q
q q
799-601-7240 Case
799-601-7270 Case
799-601-7510 Adapter for 070
10
07-10
799-601-7520 Adapter for 070
12
07-12
799-601-7530 Adapter for 070
14
07-14
799-601-7540 Adapter for 070
18
07-18
799-601-7550 Adapter for 070
20
07-20
REL-5P
REL-6P
799-601-7380 Adapter for JFC
799-601-9010 Adapter for DTM
DTM2
DT2
DT3
DT4
DT6
DT8GR
DT8B
DT8G
DT8BR
12
DT12GR
12
DT12B
12
DT12G
12
DT12BR
799-601-9210 Adapter for HD30-18
D18-8
q q
799-601-9220 Adapter for HD30-18
14
D18-14
q q
799-601-9230 Adapter for HD30-18
20
D18-20
q q
799-601-9240 Adapter for HD30-18
21
D18-21
q q
799-601-9250 Adapter for HD30-24
D24-9
q q
799-601-9260 Adapter for HD30-24
16
D24-16
q q
799-601-9270 Adapter for HD30-24
21
D24-21
q q
799-601-9280 Adapter for HD30-24
23
D24-23
q q
799-601-9290 Adapter for HD30-24
31
D24-31
q q
799-601-9310 Plate for HD30 (24-pin)

799-601-9320 T-box (for ECONO)
24
q q
q q
q q
q q
40-200
47

Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification
symbol
799-601-2700
Part name
T-adapter kit
799-601-2500
Part No.
Number of pins
SEN03938-02
799-601-9330 Case
799-601-9340 Case
40
DRC-40
q
q
24
DRC-24
799-601-9410* Socket for engine (CRI-T2)
Adapter for engine (CRI-T2)

799-601-9420 Adapter for engine (CRI-T3) PFUEL
Oil pressure sensor
A3
q q
q q
1,2,3
795-799-5520* Socket for engine (HPI-T2)
Socket for engine (HPI-T2)

Temperature sensor
q q
q q
799-601-9430*
795-799-5540*
Socket for engine (CRI-T2)

Socket for engine (CRI-T3) PCV
Socket for engine (HPI-T2)

Socket for engine (CRI-T3) TIM
795-799-5460 Cable for engine (HPI-T2)
799-601-4110 Adapter for engine (140-T3) PIM
ITT3N
q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
FCIN
q q

799-601-4140
Atomosphere pressure
FCIG
q q
799-601-4150 Adapter for engine (CRI-T3) POIL
FCIB
q q

799-601-4160
Oil pressure switch
4160
q q
799-601-4180 Adapter for engine (CRI-T3) PEVA
4180
q q
799-601-4190*

Commonrail pressure
1,2,3L
q q
799-601-4230*

Air intake pressure/temperature
1,2,3,4C
q q
799-601-4240* Socket for engine (CRI-T3) PAMB
1,2,3A
q q
799-601-4250* Socket for engine (CRI-T3) PIM
1,2,3B
q q
799-601-4330* Socket for engine (CRI-T3) G
1,2,3,G
q q
q q
799-601-4340*

Pump actuator
2,PA
799-601-4380*
Socket for engine (CRI-T3)(95)

Air intake pressure/temperature
1,2,3,4T
q
q q
799-601-4260 Adapter for controller (ENG)
DTP4
50
DRC50
60
DRC60
q
q
799-601-4390* Socket for controller (95 ENG)
60
799-601-4280* Box for controller (PUMP)
121
799-601-9720 Adapter for controller (HST)
16
HST16A
16
HST16B
26
HST26A
2,
3,
4,
799-601-9890
Multi-adapter for
DT2 4 and DTM2
* Shows not T-adapter but socket.
40-200
48

SEN03938-02
40-200
49
SEN03938-02

2009 KOMATSU
All Rights Reserved
40-200
50
SEN03939-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
40 Troubleshooting
40
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...................................................................................... 6
Failure code [AA1ANX] Air cleaner: Clogging................................................................................................. 8
Failure code [AB00L6] Alternator R system: Hot short ................................................................................. 10
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage ................... 12
Failure code [B@BAZG] Engine: Oil pressure reduction .............................................................................. 14
Failure code [B@BAZK] Engine oil: Low level .............................................................................................. 15
Failure code [B@BCNS] Engine: Overheat .................................................................................................. 16
Failure code [B@BCZK] Engine: Low coolant level...................................................................................... 18
Failure code [B@C6NS] Front brake: High oil temperature.......................................................................... 20
Failure code [B@CRNS] HST: High oil temperature..................................................................................... 21
40-310

Failure code [2G40ZG] Brake: Oil pressure reduction
SEN03939-00

Action code
Failure code
E03
2G40ZG
Contents of
trouble
Trouble
Brake: Oil pressure reduction

(Machine monitor system)
While engine was running (for at least 30 seconds), brake oil pressure sensor detected that oil pressure 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
Central warning lamp, alarm buzzer and caution lamp operate for a maximum of 30 seconds after the
machine monitor
engine starts, but no failure codes are displayed.
if cause of failure disappears, system resets itself.
Problem that
appears on
machine
Related
information
If machine is used as it is, brake may not work.

Input state (ON/OFF) from brake oil pressure sensor can be checked with monitoring function
(Monitoring code: MONITOR PANEL 40902 D-IN-16).
Causes
1 Brake oil pressure reduction
System is normal.
a Carry out troubleshooting for hydraulic and mechanical systems.
a Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
Defective brake oil pressure

sensor (Internal defect)
T12 (male)
Between (1) (2)

Possible causes
and standard
value in normal
state
Oil pressure
Resistance
Min. 5.88 MPa

{60 kg/cm2}
Max. 1 z
Max. 3.92 MPa

{40 kg/cm2}
Min. 1 Mz
a Prepare with starting switch OFF, then carry out troubleshooting

without turning starting switch ON.
Disconnection in wiring harness (Disconnection in wiring Wiring harness between T12 (female) (1)
3
or defective contact in con- L26 (female) (1)
nector)
Wiring harness between T12 (female) (2)
ground
Resistance
Max. 1 z
Resistance
Max. 1 z
a Prepare with starting switch OFF, then turn starting switch ON

and carry out troubleshooting.
L26
4 Defective machine monitor
Between (1) ground
40-310
Oil pressure
Voltage
Min. 5.88 MPa

{60 kg/cm2}
Max. 1 V
Max. 3.92 MPa

{40 kg/cm2}
20 30 V

SEN03939-00
40-310

Failure code [6091NX] HST filter: Clogging
SEN03939-00

Action code
Failure code
E01
6091NX
Contents of
trouble
Trouble
HST filter: Clogging

When HST oil temperature was above 50C, HST oil filter clogging sensor signal circuit was closed
(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
machine
Related
information
If machine is used as it is, foreign matter may enter HST circuit.

The input state from the HST oil filter clogging sensor can be checked with monitoring function
(Monitoring code: MONITOR PANEL 40903 D-IN-24)
Causes
1 Clogged HST oil filter

System is normal.
a Check HST oil filter directly.
Possible causes
and standard
value in normal
state
Defective HST oil filter clogging sensor (Internal defect)
T13
Filter condition
Resistance
Between T13
ground
Not clogged (Normal)
Min. 1 Mz
Clogged
Max. 1 z

Disconnection in wiring harness (Disconnection in wiring Wiring harness between T13 L26 (female)
3
or defective contact in con- (5)
nector)
Wiring harness between HST oil filter clogging sensor body ground
Resistance
Max. 1 z
Resistance
Max. 1 z

L26
Between (5) ground
Filter condition
Voltage
Not clogged (Normal)
20 30 V
Clogged
Max. 1 V
40-310

SEN03939-00
40-310

Failure code [989FN1] Travel speed: Overrun alarm
SEN03939-00

Action code
Failure code
E02
989FN1
Contents of
trouble
Trouble
Travel speed: Overrun alarm

Travel speed exceeded 45 km/h.

Auto-decelerator does not work at speed higher than 40 km/h.
Action of
machine monitor
Problem that
appears on
machine
Related
information
If machine is used as it is, brake etc. may be damaged.
If [DW26KA] or [DW26KY] is displayed, carry out troubleshooting for it first.
Causes
Possible causes
and standard
value in normal
state
40-310
1 Overrun
System is normal (when machine is used as it overruns by accelerating on sharp downhill road etc.)
a Check using condition and teach operator correct using method.
a Check related components for damage.
If alarm is turned ON while travel speed is below limit, machine

monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried out.)

SEN03939-00
40-310

Failure code [AA1ANX] Air cleaner: Clogging
SEN03939-00

Action code
Failure code
E01
AA1ANX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Air cleaner: Clogging

When the engine is started, the air cleaner clogging sensor circuit is OPEN.
Turns the air cleaner clogging caution lamp ON.
If problem is removed, system is returned to normal operating state.
The engine does not start or pick up easily, its output is insufficient, and its exhaust gas color is
black.
The input state (ON/OFF) from the air cleaner clogging sensor can be checked with the monitoring
function (Code: MONITOR PANEL, 40902, D-IN-20).
Method of reproducing failure code: Start engine
Causes
1 Clogged air cleaner
Defective dust indicator

(Internal short circuit)

The air cleaner may be clogged. Check it directly.
troubleshooting.
Replace the dust
indicator
If the condition becomes normal, the trouble

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
troubleshooting.
short circuit)
Possible causes
and standard
value in normal
state
When dust indicator relay (L112) is replaced with a relay of the

same type (5-pin type), if the condition becomes normal, the
exchange relay is defective.
Disconnection in wiring harness
4
(Disconnection or defective
contact in connector)

Wiring harnesses between L112 (female)
(6) L26 (female) (3)
Resistance
Max. 1 z
Wiring harnesses between L112 (female)

(3) chassis ground
Resistance
Max. 1 z

Grounding fault in wiring harwithout turning starting switch ON.
5 ness
Resis(Contact with ground circuit) Wiring harness between L112 (female) (6)
Min. 1 Mz
L26 (female) (3) and chassis ground
tance
troubleshooting.
L26
Between (3) and
chassis ground
40-310
Dust indicator
Voltage
Normal (Air cleaner is

normal)
Max. 1 V
Defective (Air cleaner

is clogged)
20 30 V

SEN03939-00
Circuit diagram related to dust indicator
40-310

Failure code [AB00L6] Alternator R system: Hot short
SEN03939-00

Action code
Failure code
E01
AB00L6
Contents of
trouble
Trouble
Alternator R system: Hot short

When engine is stopped, alternator terminal R input voltage is above 12 V.
Action of
Turns the charge circuit error caution lamp ON.
machine monitor
Problem that
appears on
machine
Related
information
After the engine is started, just turning on the starting switch runs the service meter.
The input state (voltage) from the alternator can be checked with the monitoring function (Monitoring
code: HST 04302 ALTERNATOR R).
Method of reproducing failure code: Turn the starting switch ON.
Causes

troubleshooting.
Possible causes
and standard
value in normal
state
Defective alternator
(Internal trouble)
Hot short in wiring harness

(Contact with 24V circuit)
Alternator
Engine
Voltage
Wiring harness
between E02
(female) (1) ground
Running (Throttle:
Above 1/2)
27.5 29.5 V
Holds in position
Max. 1.5 V

Wiring harnesses between E02 (female) (1)
L25 (female) (18), circuit branch end and
ground
Voltage
Max. 1 V
troubleshooting.
L25
Between (18) and
ground
40-310
10
Engine
Voltage
Running
(Throttle: Above 1/2)
27.5 29.5 V
Holds in position
Max. 1.5 V

SEN03939-00
40-310
11

Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage
SEN03939-00
Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/

Low charge voltage
Action code
Failure code
E03
Contents of
trouble
AB00MA
Trouble
Alternator R system: Ground fault/Disconnection/Low charge voltage

While the engine is running, the alternator terminal R input voltage is below 5 V.
Action of
Turns the charge circuit failure caution lamp ON.
machine monitor Turns the centralized warning lamp and alarm buzzer ON.
Problem that
appears on
machine
Related
information
Deterioration of battery or insufficient charging

Engine does not start.
The input state (voltage) from the alternator can be checked with the monitoring function (Monitoring
code: HST 04302 ALTERNATOR R).
Causes
1 The battery is deteriorated.

The battery may be deteriorated. Check it directly.
troubleshooting.
Possible causes
and standard
value in normal
state
(Internal trouble)

3
Alternator
Engine
Voltage
Wiring harness
between E02
(female) (1) ground
Running (Throttle:
Above 1/2)
27.5 29.5 V
Holds in position
Max. 1.5 V

Wiring harnesses between E02 (female) (1)
L25 (female) (18)
Resistance
Max. 1 z
a Prepare by turning starting switch OFF and then start engine to

carry out troubleshooting.
Grounding fault in wiring har4 ness
Wiring harness between E02 (female) (1)
Resis(Contact with ground circuit) L25 (female) (18) circuit branch end and
Min. 1 Mz
tance
ground
troubleshooting.
L25
Between (18) and
ground
40-310
12
Engine
Voltage
Running (Throttle:
Above 1/2)
27.5 29.5 V
Holds in position
Max. 1.5 V

Failure code [AB00MA] Alternator R system: Ground fault/Disconnection/Low charge voltage
SEN03939-00
40-310
13

Failure code [B@BAZG] Engine: Oil pressure reduction
SEN03939-00
Failure code [B@BAZG] Engine: Oil pressure reduction

Action code
Failure code
E03
B@BAZG
Contents of
trouble
Trouble
Engine: Oil pressure reduction

(Engine controller system)
While engine is run, engine oil pressure became lower than operating range.
Action of
Limits output and continues operation (Limits fuel injection rate and engine speed).
Problem that
appears on
machine
Related
information
Engine output lowers.
Causes
1
Possible causes
and standard
value in normal
state
Low engine oil pressure

Engine oil has potentially gone low. Check the pressure and if it is
(When the system is normal) below the specified level, locate and eliminate the cause.
Defective engine oil pressure

2 switch
(Internal trouble)
troubleshooting.
OIL PRESSURE SWITCH
Resistance
Between terminals
Min. 1 Mz

Ground fault in wiring harness
3
(Contact with GND circuit)
Wiring harnesses between EC1 (female)
ResisMin. 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
14

Failure code [B@BAZK] Engine oil: Low level
SEN03939-00
Failure code [B@BAZK] Engine oil: Low level

Action code
Failure code
E01
B@BAZK
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Engine oil: Low level

While engine is stopped, the engine oil level sensor circuit was detected to have remained in OPEN
condition for more than 2 seconds.
(This error, however, is not detected for 5 minutes from the engine stop)
An error being detected at stopping the engine remains as the error after the engine is started again
until the normal condition is recovered.
Turns the engine oil level caution lamp ON.
The engine oil level is low (The engine may be broken).
The input state (ON/OFF) from the engine level sensor can be checked with the monitoring function
(Code: MONITOR PANEL, 40903, D-IN-29).
Causes
1 Low engine oil level

The engine oil level may be low. Check it directly.
Defective engine oil level

2 sensor
(Internal disconnection)
Possible causes
and standard
value in normal
state

3
contact)
E26 (male)
Between (1) and
chassis ground
Engine oil level
Resistance
Oil level is normal
Max. 1 z
Oil level is insufficient (low level)
Min. 1 Mz

Wiring harnesses between L27 (female) (11)
E26 (female) (1)
Resistance
Max. 1 z

L27 (female)
Engine oil level
Voltage
Wiring harness
between (11) chassis ground
Oil level is normal
20 30 V
Oil level is insufficient (low level)
Max. 1 V
40-310
15

Failure code [B@BCNS] Engine: Overheat
SEN03939-00

Action code
Failure code
E02
B@BCNS
Contents of
trouble
Trouble
Engine: Overheat
While engine was running, engine coolant temperature sensor signal circuit detected engine coolant
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
machine
Related
information
Engine output decreases.

Engine coolant temperature can be checked with monitoring function.
(Monitoring code: ENGINE 04104 COOLANT TEMP (C))
Causes
Possible causes
and standard
value in normal
state
Engine coolant overheat

(when system is normal)
Engine coolant may be overheating. Remove cause of overheat.
Defective engine coolant

temperature sensor system
If cause 1 is not detected, engine coolant temperature sensor system may be defective. Carry out troubleshooting for failure codes
[CA144] and [CA145].
40-310
16
If causes 1 and 2 are not detected, engine controller may be defective. Carry out troubleshooting for failure codes [CA144] and
[CA145].

SEN03939-00
40-310
17

Failure code [B@BCZK] Engine: Low coolant level
SEN03939-00

Action code
Failure code
E01
B@BCZK
Contents of
trouble
Trouble
Engine: Low coolant level

Radiator coolant level switch signal circuit was opened (disconnected from GND) for 30 seconds.
Action of
Turns radiator coolant level caution lamp ON.
machine monitor
Problem that
appears on
machine
Related
information
If machine is used as it is, engine may overheat.

Operation of radiator coolant level switch can be checked with monitoring function.
Causes
1
Low radiator sub-tank coolant level

System is normal.
a Radiator sub-tank coolant level may be low. Check and add coolant, if necessary.
Defective radiator coolant

level switch (Internal defect)
B05 (male)
Between (1) (2)

Possible causes
and standard
value in normal
state
Sub-tank coolant
level
Resistance
Above low level

(Normal)
Max. 1 z
Below low level
Min. 1 Mz

Disconnection in wiring harness (Disconnection in wiring Wiring harness between L27 (female) (10)
3
or defective contact in con- B05 (female) (1)
nector)
Wiring harness between B05 (female) (2)
ground
Resistance
Max. 1 z
Resistance
Max. 1 z

L27
Between (10)
ground
40-310
18
Sub-tank coolant
level
Voltage
Above low level

(Normal)
Max. 1 V
Below low level
20 30 V

SEN03939-00
40-310
19

Failure code [B@C6NS] Front brake: High oil temperature
SEN03939-00
Failure code [B@C6NS] Front brake: High oil temperature

Action code
Failure code
E02
B@C6NS
Contents of
trouble
Trouble
Front brake: High oil temperature

Front brake (axle) high oil temperature was detected (Details are as follows).
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
machine monitor Turns brake oil temperature caution lamp ON.
Problem that
appears on
machine
Related
information
If machine is used as it is, brake may be damaged.

If temperature above 120C is detected for 5 seconds continuously, only caution lamp is turned ON
as preliminary warning.
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))
Causes
Possible causes
and standard
value in normal
state
20
System is normal.
a Front brake (Axle) oil may be overheated. Remove cause of overheat.
Front brake (Axle) high oil

temperature
If cause 1 is not detected, brake oil temperature sensor system may

Defective brake oil temperabe defective. Carry out troubleshooting for failure codes [DGR2KB]
ture sensor
and [DGR2KZ].
40-310
If causes 1 and 2 are not detected, machine monitor may be defective. Carry out troubleshooting for failure codes [DGR2KB] and
[DGR2KZ].

Failure code [B@CRNS] HST: High oil temperature
SEN03939-00
Failure code [B@CRNS] HST: High oil temperature

Action code
Failure code
E02
B@CRNS
Contents of
trouble
Trouble
HST: High oil temperature

HST oil temperature higher than 105C was detected for 10 seconds continuously.
Action of
machine monitor Turns HST oil temperature caution lamp ON.
Problem that
appears on
machine
Related
information
If machine is used as it is, hydraulic system equipments may be damaged.

HST oil temperature can be checked with monitoring function.
(Monitoring code: MONITO PANEL 04408 HST OIL TEMP (C))
(Monitoring code: MONITO PANEL 04409 HST OIL TEMP (V))
Causes
Possible causes
and standard
value in normal
state
1 HST high oil temperature

System is normal.
a HST oil may be overheated. Remove cause of overheat.
Defective HST oil temperature sensor
If cause 1 is not detected, HST oil temperature sensor system may

be defective. Carry out troubleshooting for failure code [DGH1KX].
If causes 1 and 2 are not detected, machine monitor may be defective. Carry out troubleshooting for failure code [DGH1KX].
40-310
21
SEN03939-00

2008 KOMATSU
All Rights Reserved
40-310
22
SEN03940-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
40 Troubleshooting
40

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
40-320
SEN03940-00

Failure code [CA342] Calibration code inconsistency................................................................................... 48
Failure code [CA351] Injectors drive circuit error .......................................................................................... 50
40-320

Failure code [CA111] Abnormality in engine controller
SEN03940-00
Failure code [CA111] Abnormality in engine controller

Action code
Failure code
E03
CA111
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Trouble
Abnormality in engine controller

Abnormality occurred in memory of engine controller or power supply circuit.

Turns the centralized warning lamp and alarm buzzer ON.
The engine does not start.
Causes
Possible defect in engine controller (Troubleshooting cannot be carried out.)
40-320

Failure code [CA115] Engine Ne or Bkup speed sensor error
SEN03940-00

Action code
Failure code
E03
CA115
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
40-320
Trouble
Engine Ne or Bkup speed sensor error

Abnormality occurred in signals of engine Ne speed sensor and engine Bkup speed sensor circuit.
Engine stops.
Causes
1
Defective connection of sen- Check Ne speed sensor and Bkup speed sensor directly for defecsor connector
tive connection (wrong connection).

SEN03940-00
40-320

Failure code [CA122] Charge pressure sensor high error
SEN03940-00

Action code
Failure code
E03
CA122
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Charge pressure sensor high error

High voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor.
Fixes charge pressure (boost pressure) and continues operation.
Engine output drops.
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).
The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
with the monitoring function (Code: ENGINE, 36502, CHG PRESS-A).
Causes
1
Defective sensor power sup- If failure code [CA227] is indicated simultaneously, carry out troubleply 2 system
shooting for it first.
Defective boost pressure

BOOST PRESS & IMT
Voltage
sensor and temperature sen2
Voltage
4.75 5.25 V
sors [pressure signal system] Between (2) and (4)
(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.
Possible causes
and standard
value in normal
state

Hot short (Short circuit with
3 5V, 24V circuit) in wiring har- Wiring harness between EC1 (female) (44)
ness
BOOST PRESS & IMT (female) (1) and
Voltage Max. 1 V
ground
Short circuit in wiring harWiring harnesses between EC1 (female)

4 ness
(with another wiring harness) (44) BOOST PRESS & IMT (female) (1)
and EC1 (female) (47) BOOST PRESS &
IMT (female) (4).
Defective wiring harness

connector
Resistance
Min.
100 kz
Connecting parts among boost pressure sensor/temperature sensor, engine wiring harness, and engine controller are suspected.
Inspect them directly.
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
EC1
Between (37) and
(47)
40-320
Voltage
Power supply
4.75 5.25 V

SEN03940-00
40-320

Failure code [CA123] Charge pressure sensor low error
SEN03940-00

Action code
Failure code
E03
CA123
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Charge pressure sensor low error

Low voltage is detected in pressure signal circuit of boost pressure sensor and temperature sensor.
Fixes charge pressure (boost pressure) and continues operation.
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).
The input state (voltage) from the charge pressure sensor (boost pressure sensor) can be checked
with the monitoring function (Code: ENGINE, 36502, CHG PRESS-A).
Causes
1
Defective boost pressure

sensor or temperature sen2
sor [pressure signal circuit]
(Internal trouble)
Possible causes
and standard
value in normal
state
BOOST PRESS & IMT

Between (2) and (4)
Power supply
Voltage
4.75 5.25 V


Wiring harness between EC1 (female) (44)
ResisMin.
(Contact with ground circuit) BOOST PRESS & IMT (female) (1) and
tance
100 kz
ground
Short circuit in wiring harWiring harnesses between EC1 (female)

4 ness
(with another wiring harness) (44) BOOST PRESS & IMT (female) (1),
EC1 (female) (47) BOOST PRESS & IMT
(female) (4)

connector
Resistance
Min.
100 kz
Loose connector, broken lock and broken seal
EC1
Between (37) and
(47)
40-320
Voltage
Power supply
4.75 5.25 V

SEN03940-00
40-320

Failure code [CA131] Throttle sensor high error
SEN03940-00

Action code
Failure code
E03
CA131
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Throttle sensor high error

High voltage was detected in the throttle sensor signal circuit.

Runs the engine at position of throttle 0% when accelerator pedal is OFF and at 50% when it is ON.
The engine does not reach full throttle.
The input state (accelerator pedal opening ratio) from the throttle sensor can be checked with the
monitoring function (Code: ENGINE, 31701, THROTTLE POS).
The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
ENGINE, 31707, THROTTLE POS).
Causes
Defective throttle sensor

power supply system
If failure code [CA2185] is indicated simultaneously, carry out troubleshooting for it first.
Defective accelerator pedal

2
(Internal trouble)
PD1
Accelerator pedal
Voltage
Between (1) and (3)
All range
(Power supply)
4.75 5.25 V
When released
0.50 0.80 V
When pressed
3.70 4.00 V
Between (2) and (3)
Sensor voltage is measured with wiring harness connected. Accordingly, if voltage is abnormal, check wiring harness and controller for
another cause of trouble before judgment
Possible causes
and standard
value in normal
state

3 5V, 24V circuit) in wiring harWiring harness between EC2 (female) (9)
ness
Voltage Max. 1 V
PD1 (female) (2) and ground
Short circuit in wiring har4 ness
ResisMin.
(with another wiring harness) PD1 (female) (2), EC2 (female) (22) PD1
tance
100 kz
(female) (1)

connector
Connecting parts among accelerator pedal, engine unit wiring harness, and engine controller are suspected. Inspect them directly.
Loose connector, broken lock, broken seal
EC2
Accelerator pedal
Voltage
Between (22) and

(23)
All range
(Power supply)
4.75 5.25 V
When released
0.50 0.80 V
When pressed
3.70 4.00 V
Between (9) and (23)
40-320
10

SEN03940-00
40-320
11

Failure code [CA132] Throttle sensor low error
SEN03940-00

Action code
Failure code
E03
CA132
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Throttle sensor low error

Low voltage was detected in the throttle sensor signal circuit.

The input state (accelerator pedal opening ratio) from the throttle sensor can be checked with the
monitoring function (Code: ENGINE, 31701, THROTTLE POS).
The input state (voltage) from the throttle sensor can be checked with the monitoring function (Code:
ENGINE, 31707, THROTTLE POS).
Causes
Defective throttle sensor

power supply system

2
(Internal trouble)
PD1
Accelerator pedal
Voltage
Between (1) and (3)
All range
(Power supply)
4.75 5.25 V
When released
0.50 0.80 V
When pressed
3.70 4.00 V
Between (2) and (3)
Possible causes
and standard
value in normal
state

Ground fault in wiring harwithout turning starting switch ON.
ness
3
(Short circuit with ground cir- Wiring harness between EC2 (female) (9)
ResisMin.
cuit)
tance
100 kz
ResisMin.
(with another wiring harness) PD1 (female) (2), EC2 (female) (23) PD1
tance
100 kz
(female) (3)

connector
Connecting parts among fuel control dial, engine unit wiring harness, and engine controller are suspected. Inspect them directly.
EC2
Accelerator pedal
Voltage
Between (22) and

(23)
All range
(Power supply)
4.75 5.25 V
When released
0.50 0.80 V
When pressed
3.70 4.00 V
40-320
12

SEN03940-00
40-320
13

Failure code [CA144] Coolant sensor high error
SEN03940-00

Action code
Failure code
E01
CA144
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Coolant sensor high error

High voltage is detected in coolant temperature sensor signal circuit.

Fixes engine coolant temperature and continues operation.
Exhaust smoke becomes white
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).
The input state (voltage) from the engine coolant temperature sensor can be checked with the monitoring function (Code: ENGINE, 04105, COOLANT TEMP).
Causes

Defective coolant tempera1 ture sensor

(Internal trouble)
COOLANT TEMP
(male)
Between (A) and (B)

2
Possible causes
and standard
value in normal
state
Coolant temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z

COOLANT TEMP (female) (B)
Resistance
Max. 10z

COOLANT TEMP (female) (A)
Resistance
Max. 10z

Short circuit in wiring harWiring harness among all pins between EC1
3 ness
(with another wiring harness) (female) (15) EC1 (female)
(With all connectors of wiring harness disconnected)

connector
Resistance
Min.
100 kz
Connecting parts among coolant temperature sensor, engine wiring

harness, and engine controller are suspected. Inspect them directly.
EC1 (female)

Between (15) and
(38)
40-320
14
Coolant temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z

SEN03940-00
40-320
15

Failure code [CA145] Coolant sensor low error
SEN03940-00

Action code
Failure code
E01
CA145
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Coolant sensor low error

Low voltage is detected in coolant temperature sensor signal circuit.

Fixes engine coolant temperature and continues operation.
Exhaust smoke becomes white
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).
The input state (voltage) from the engine coolant temperature sensor can be checked with the monitoring function (Code: ENGINE, 04105, COOLANT TEMP).
Causes

COOLANT TEMP
(male)
Defective coolant tempera1 ture sensor

(Internal trouble)
Possible causes
and standard
value in normal
state
Between (A) and (B)
Between (B) and

ground
Coolant temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
All range
Min. 100 kz

ness
2
ResisMin.
cuit)
COOLANT TEMP (female) (B) and ground
tance
100 kz

Wiring harness among all pins between EC1
(with another wiring harness) (female) (15) EC1 (female) (With all connectors of wiring harness disconnected)
40-320
16

connector
Resistance
Min.
100 kz
Connecting parts among coolant temperature sensor, engine wiring


Causes
SEN03940-00

EC1 (male)
Possible causes
and standard
value in normal
state
Between (15) and

(38)
Between (15) and

ground
Coolant temperature
Resistance
0C
30 37 kz
25C
9.3 10.7 kz
50C
3.2 3.8 kz
80C
1.0 1.3 kz
95C
700 800 z
All range
Min. 100 kz
40-320
17

Failure code [CA153] Charge temperature sensor high error
SEN03940-00

Action code
Failure code
E01
CA153
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Charge temperature sensor high error

High voltage is detected in temperature signal circuit of boost pressure sensor and temperature sensor.
Fixes charge temperature and continues operation.
Exhaust smoke becomes white.
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).
The input state (voltage) from the charge temperature sensor (boost temperature sensor) can be
checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP).
Causes

Defective temperature signal circuit of boost pressure

1
and temperature sensor
(Internal trouble)
BOOST PRESS &

IMT (male)
Between (3) and (4)

2
Possible causes
and standard
value in normal
state
Charge temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z

BOOST PRESS & IMT (female) (3)
Resistance
Max. 10z

BOOST PRESS & IMT (female) (4)
Resistance
Max. 10z

ResisMin.
(with another wiring harness) (female) (23) EC1 (female) (With all contance
100 kz
nectors of wiring harness disconnected)

connector
EC1 (female)

Between (23) and
(47)
40-320
18
Charge temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z

SEN03940-00
40-320
19

Failure code [CA154] Charge temperature sensor low error
SEN03940-00

Action code
Failure code
E01
CA154
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Charge temperature sensor low error

Low voltage is detected in temperature signal circuit of boost pressure sensor and temperature sensor.
Exhaust smoke becomes white.
Boost temperature-based engine protection function does not function.
Causes

BOOST PRESS &

IMT (male)
Defective temperature signal circuit of boost pressure
1 sensor and temperature sensor
Between (2) and (1)
(Internal trouble)
Between (2) and
ground
Possible causes
and standard
value in normal
state
Charge temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z
All range
Min. 100 kz

ness
2
ResisMin.
BOOST PRESS & IMT (female) (3) and
cuit)
tance
100 kz
ground

40-320
20

connector
Resistance
Min.
100 kz

Causes
SEN03940-00

Possible causes
and standard
value in normal
state
EC1 (female)
Between (23) and

(47)
Between (23) and

ground
Charge temperature
Resistance
0C
29 36 kz
25C
9 11 kz
40C
4.9 5.8 kz
100C
600 700 z
All range
Min. 100 kz
40-320
21

Failure code [CA155] Derating of speed by abnormally high charge temperature
SEN03940-00
Failure code [CA155] Derating of speed by abnormally high charge

temperature
Action code
Failure code
E03
CA155
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Limits output and continues operation.

Engine stops
22
Cooling performance deterioration of the after cooler is suspected.

Inspect the following points directly.
Drop in cooling performance
1
Malfunction of hydraulic drive fan
of aftercooler
Lack of cooling air
Clogged aftercooler fin
2
Abnormally high temperature at turbocharger outlet
40-320
Derating of speed by abnormally high charge temperature

Temperature signal of boost pressure sensor and temperature sensor is above upper control limit.
Causes
Possible causes
and standard
value in normal
state
Inspect related parts directly.

If causes 1 2 are not detected, engine controller may be defective.
(Since trouble is in system, troubleshooting cannot be carried out.)

Failure code [CA155] Derating of speed by abnormally high charge temperature
SEN03940-00
40-320
23

Failure code [CA187] Sensor power supply 2 low error
SEN03940-00

Action code
Failure code
E03
CA187
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Sensor power supply 2 low error

Low voltage is detected in sensor power supply 2 circuit.
Fixes boost pressure and continues operation.

Causes

a Disconnect connector with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
Defective sensor or wiring

harness
Possible causes
and standard
value in normal
state

connector
40-320
24
Disconnect devices at
right in order. If mark
E of failure code disappears after reproduction operation is
conducted, that
device or wiring harness has a defect in
it.
Boost pressure,
temperature sensor
BOOST PRESS &

IMT
Common rail
pressure sensor
FUEL RAIL PRESS
Bkup sensor
CAM SENSOR
Engine wiring
harness
EC1
Connecting parts among each sensor, engine wiring harness, and

engine controller are suspected. Inspect them directly.

SEN03940-00
40-320
25

Failure code [CA221] Atmospheric pressure sensor high error
SEN03940-00

Action code
Failure code
E01
CA221
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Ambient pressure sensor high error

High voltage is detected in atmospheric pressure sensor circuit.

Fixes atmospheric pressure and continues operation.
Engine does not start easily.
The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: ENGINE, 37400, AMBIENT PRESS).
The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
function (Code: ENGINE, 37402, AMBIENT PRESS).
Causes
1
Possible causes
and standard
value in normal
state
AMBAIR PRESSURE
Voltage
Defective atmospheric presPower supply
4.75 5.25 V
sure sensor (Internal trouble) Between (1) and (2)

3 5V, 24V circuit) in wiring har- Wiring harness between EC1 (female) (3)
ness
AMBAIR PRESSURE (female) (3) and
Voltage Max. 1 V
ground
Short circuit in wiring harWiring harness between EC1 (female) (3)

4 ness
(with another wiring harness) AMBAIR PRESSURE (female) (3), EC1
(female) (33) AMBAIR PRESSURE
(female) (1)

connector
Resistance
Min.
100 kz
Connecting parts among atmospheric pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them
directly.
EC1
Between (33) and
(38)
40-320
26
Voltage
Power supply
4.75 5.25 V

SEN03940-00
40-320
27

Failure code [CA222] Atmospheric sensor low error
SEN03940-00

Action code
Failure code
E01
CA222
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Atmospheric sensor low error

Low voltage is detected in atmospheric pressure sensor circuit.

Engine does not start easily.
The input state (atmospheric pressure) from the atmospheric pressure sensor can be checked with
the monitoring function (Code: ENGINE, 37400, AMBIENT PRESS).
The input state (voltage) from the atmospheric pressure sensor can be checked with the monitoring
function (Code: ENGINE, 37402, AMBIENT PRESS).
Causes
1
Possible causes
and standard
value in normal
state
AMBAIR PRESSURE
Voltage
Defective atmospheric presPower supply
4.75 5.25 V
sure sensor (Internal trouble) Between (1) and (2)

ness
3
Wiring
harness between EC1 (female) (3)
(Short circuit with ground cirResisMin.
AMBAIR
PRESSURE (female) (3) and
cuit)
tance
100 kz
ground

4 ness
(with another wiring harness) AMBAIR PRESSURE (female) (3), EC1
(female) (38) AMBAIR PRESSURE
(female) (2)

connector
Resistance
Min.
100 kz
directly.
EC1
Between (33) and
(38)
40-320
28
Voltage
Power supply
4.75 5.25 V

SEN03940-00
40-320
29

Failure code [CA227] Sensor power supply 2 high error
SEN03940-00

Action code
Failure code
E03
CA227
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Sensor power supply 2 high error

High voltage is detected in sensor power supply 2 circuit.
Fixes boost pressure and continues operation.

Causes
Possible causes
and standard
value in normal
state

connector

If cause 1 is not detected, engine controller may be defective.

40-320
30

Failure code [CA234] Engine overspeed
SEN03940-00
Failure code [CA234] Engine overspeed

Action code
Failure code
E02
CA234
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Engine Overspeed
Engine speed is above upper control limit.

Stops injection of injector until engine speed drops to normal level.
Engine speed fluctuates.
Engine speed can be checked by monitoring function (Code: ENGINE, 01001, ENG SPEED).
Method of reproducing failure code: Start engine and running at high idle.
Causes
Possible causes
and standard
value in normal
state
1 Use of improper fuel

2

Check fuel used directly.
Improper way of speed con- Way of speed control may be improper. Teach proper way of use to
trol
operator.
If causes 1 and 2 are not detected, engine controller may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)
40-320
31

Failure code [CA238] Ne speed sensor power supply error
SEN03940-00
Failure code [CA238] Ne speed sensor power supply error

Action code
Failure code
E03
CA238
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Ne speed sensor supply power error

Low voltage is detected in engine Ne speed sensor power supply circuit.

Controls Ne speed sensor with signals of Bkup speed sensor.
Starting performance is poor.
There is hunting from engine.
Causes

Possible causes
and standard
value in normal
state

harness

connector
right in order. If failure
code disappears after
reproduction operation is conducted, that
it.
Ne speed sensor
CRANK SENSOR
Engine wiring
harness
EC1

40-320
32

Failure code [CA271] IMV (IMA) Short circuit
SEN03940-00
Failure code [CA271] IMV (IMA) Short circuit

Action code
Failure code
E03
CA271
Trouble
IMV (IMA) Short circuit

Contents of
trouble
There is short circuit in supply pump actuator drive circuit.
Action of
controller
Problem that
appears on
machine
Related
information
Engine speed does not rise from low idle.

Common rail fuel pressure is above command value.
Causes

Defective supply pump actu1
ator
CP3 PUMP REGULATOR (male)
Resistance
Min. 100 kz

ness
2
Wiring
(Short circuit with ground cirResisMin.
CP3
PUMP
REGULATOR (female) (1) and
cuit)
tance
100 kz
ground
Possible causes
and standard
value in normal
state

Min.
(with another wiring harness) (female) (2) EC1 (female) (With all connec- Resistance
100 kz
tors of wiring harness disconnected)

connector
Connecting parts among supply pump actuator, engine wiring harness, and engine controller are suspected. Inspect them directly.
EC1 (female)
Resistance
Min. 100 kz
40-320
33

Failure code [CA272] IMV (IMA) Disconnection
SEN03940-00

Action code
Failure code
E03
CA272
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
IMV (IMA) Disconnection

There is disconnection in supply pump actuator drive circuit.

Engine runs, but in unstable condition.
Common rail fuel pressure is above command value.
Causes

Defective supply pump actu1
ator
CP3 PUMP REGULATOR (male)
Resistance
Max. 5 z
Between (1) and (2)

2

CP3 PUMP REGULATOR (female) (1)
Resistance
Max. 10 z

Resistance
Max. 10 z

Possible causes
and standard
value in normal
state

24V circuit) in wiring harness Wiring harness between EC1 (female) (2)
CP3 PUMP REGULATOR (female) (1) and
ground
Voltage
Max. 3 V

Min.
(with another wiring harness) (female) (2) EC1 (female) (With all connec- Resistance
100 kz
tors of wiring harness disconnected)

connector
40-320
34
EC1 (female)
Resistance
Max. 5 z

SEN03940-00
40-320
35

Failure code [CA322] Injector #1 open/short error
SEN03940-00

Action code
Failure code
E03
CA322
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Injector #1 open/short error

There is disconnection or short circuit in drive circuit of injector No. 1.

There is irregular combustion or hunting.
Causes

1 Defective injector No. 1

2
INJ CYL 1
Resistance
Between (1) and (2)
Max. 2 z
Min. 100 kz

INJ CYL 1 (1)
Resistance
Max. 2 z

INJ CYL 1 (2)
Resistance
Max. 2 z

3 ness
Resis(Contact with ground circuit) Wiring harness between EC1 (female) (45)
Max. 2 z
INJ CYL 1 (1) and ground
tance
Possible causes
and standard
value in normal
state

Short circuit in wiring har(female) (45) EC1 (female) (With all con4 ness
(with another wiring harness)
(female) (53) EC1 (female) (With all connectors of wiring harness disconnected)
Resistance
Min.
100 kz
Resistance
Min.
100 kz

connector
Connecting parts among injector No. 1, engine wiring harness, and

Defective other cylinder

injector or harness
If other failure codes are indicated simultaneously, carry out troubleshooting for them.
40-320
36
EC1 (female)
Resistance
Max. 2 z
Min. 100 kz

SEN03940-00
40-320
37

SEN03940-00

Action code
Failure code
E03
CA323
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble


Causes


2
INJ CYL 5
Resistance
Between (1) and (2)
Max. 2 z
Min. 100 kz

INJ CYL 5 (1)
Resistance
Max. 2 z

INJ CYL 5 (2)
Resistance
Max. 2 z

3 ness
Max. 2 z
tance
Possible causes
and standard
value in normal
state

Resistance
Min.
100 kz
Resistance
Min.
100 kz

connector


injector or harness
40-320
38
EC1 (female)
Resistance
Max. 2 z
Min. 100 kz

SEN03940-00
40-320
39

SEN03940-00

Action code
Failure code
E03
CA324
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble


Causes


2
INJ CYL 3
Resistance
Between (1) and (2)
Max. 2 z
Min. 100 kz

INJ CYL 3 (2)
Resistance
Max. 2 z

INJ CYL 3 (1)
Resistance
Max. 2 z

3 ness
Max. 2 z
tance
Possible causes
and standard
value in normal
state

Resistance
Min.
100 kz
Resistance
Min.
100 kz

connector


injector or harness
40-320
40
EC1 (female)
Resistance
Max. 2 z
Min. 100 kz

SEN03940-00
40-320
41

SEN03940-00

Action code
Failure code
E03
CA325
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble


Causes


2
INJ CYL 6
Resistance
Between (1) and (2)
Max. 2 z
Min. 100 kz

INJ CYL 6 (2)
Resistance
Max. 2 z

INJ CYL 6 (1)
Resistance
Max. 2 z

3 ness
Max. 2 z
tance
Possible causes
and standard
value in normal
state

Resistance
Min.
100 kz
Resistance
Min.
100 kz

connector


injector or harness
40-320
42
EC1 (female)
Resistance
Max. 2 z
Min. 100 kz

SEN03940-00
40-320
43

SEN03940-00

Action code
Failure code
E03
CA331
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble


Causes


2
INJ CYL 2
Resistance
Between (1) and (2)
Max. 2 z
Min. 100 kz

INJ CYL 2 (1)
Resistance
Max. 2 z

INJ CYL 2 (2)
Resistance
Max. 2 z

3 ness
Max. 2 z
tance
Possible causes
and standard
value in normal
state

Resistance
Min.
100 kz
Resistance
Min.
100 kz

connector


injector or harness
40-320
44
EC1 (female)
Resistance
Max. 2 z
Min. 100 kz

SEN03940-00
40-320
45

SEN03940-00

Action code
Failure code
E03
CA332
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble


Causes


2
INJ CYL 4
Resistance
Between (1) and (2)
Max. 2 z
Min. 100 kz

INJ CYL 4 (1)
Resistance
Max. 2 z

INJ CYL 4 (2)
Resistance
Max. 2 z

3 ness
Max. 2 z
tance
Possible causes
and standard
value in normal
state

Resistance
Min.
100 kz
Resistance
Min.
100 kz

connector


injector or harness
40-320
46
EC1 (female)
Resistance
Max. 2 z
Min. 100 kz

SEN03940-00
40-320
47

Failure code [CA342] Calibration code inconsistency
SEN03940-00

Action code
Failure code
E03
CA342
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
40-320
48
Trouble
Calibration code inconsistency

Matching error occurred in engine controller data.

Continues the normal operation.
Engine stops or does not start.
Causes
1 Defect in related system
If another code is displayed, carry out troubleshooting for it.
Possible defect in engine controller (Troubleshooting cannot be carried out.)

SEN03940-00
40-320
49

Failure code [CA351] Injectors drive circuit error
SEN03940-00

Action code
Failure code
E03
CA351
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Injectors drive circuit error

Abnormality occurred in injector drive power supply circuit.

Limits output and continues operation (limits common rail pressure).
Exhaust smoke is black.

There is irregular combustion.
Causes
Defective fuse No. 4 of fuse

2
box FS1
If the fuse is broken, the circuit probably has a grounding fault, etc.
L107 (Male)
Resistance
Defective engine control cutBetween (1) and (2)
200 400 z
out relay 1 (L107) (Internal
3
disconnection or short cirand carry out troubleshooting.
cuit)
When engine control cut-out relay 1 (L107) is replaced with a relay
of the same type, if the condition becomes normal, the engine control cut-out relay 1 is defective.
Possible causes
and standard
value in normal
state

L108 (male)
Resistance
200 400 z
out relay 2 (L108) (Internal
4
disconnection or short cirand carry out troubleshooting.
cuit)
When engine control cut-out relay 2 (L108) is replaced with a relay
of the same type, if the condition becomes normal, the engine control cut-out relay 2 is defective.
5
40-320
50
Wiring harness between fuse No. 4 of fuse

box FS1 L107, L108 (female) (3)
Resistance
Max.
0.5 z
Wiring harness between L107 (female) (5),

L108 (female) (5) EC3 (female) (3), (4)
Resistance
Max.
0.5 z
Wiring harness between EC3 (female) (1),

(2) ground
Resistance
Max.
10 z

(Since trouble is in the system, troubleshooting cannot be carried
out.)

SEN03940-00
40-320
51

SEN03940-00

Action code
Failure code
E03
CA352
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Sensor power supply 1 low error

Low voltage is detected in sensor power supply 1 (5V) circuit.

Causes


1
harness
Possible causes
and standard
value in normal
state
52
Atmospheric pressure sensor
AMBAIR PRESSURE
Engine wiring
harness
EC1

connector
directly.

40-320
code disappears after
reproduction operation is conducted, that
it.

SEN03940-00
40-320
53

SEN03940-00

Action code
Failure code
E03
CA386
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Trouble
Sensor power supply 1 high error

High voltage is detected in sensor power supply 1 (5V) circuit.

Causes

connector
directly.
If cause 1 is not detected, engine controller may be defective.

40-320
54

SEN03940-00
40-320
55
SEN03940-00

2008 KOMATSU
All Rights Reserved
40-320
56
SEN03941-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
40 Troubleshooting
40

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
40-330
SEN03941-01
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
SEN03941-01
40-330

Failure code [CA428] Abnormally high level in water sensor
SEN03941-01

Action code
Failure code
E01
CA428
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Abnormally high level in water sensor

High voltage occurred in fuel water sensor

None in particular.
Water separator monitor does not indicate normally.
Causes

1 Defective fuel water sensor

2
Possible causes
and standard
value in normal
state
E42 (female)
Resistance
Between (1) and (2)
Max. 10 z

E42 (male) (1)
Resistance
Max. 10 z

E42 (male) (2)
Resistance
Max. 10 z



connector
Resistance
Min.
100 kz
Connecting parts among fuel water sensor, engine wiring harness,

and engine controller are suspected. Inspect them directly.
40-330
EC1 (female)
Resistance
Max. 10 z

SEN03941-01
40-330

Failure code [CA429] Abnormally low level in water sensor
SEN03941-01

Action code
Failure code
E01
CA429
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Abnormally low level in water sensor

Low voltage occurred in fuel water sensor

None in particular.
Water separator monitor does not indicate normally.
Causes

1 Defective fuel water sensor
E42 (female)
Resistance
Between (1) and (2)
Max. 10 z
Min. 100 kz

2 ness
Wiring
ResisMin.
(Contact with ground circuit)
E42 (male) (1) and ground
tance
100 kz
Possible causes
and standard
value in normal
state

ResisMin.
100 kz

connector
Connecting parts among fuel water sensor, engine wiring harness,

40-330
EC1 (female)
Resistance
Max. 10 z
Min. 100 kz

SEN03941-01
40-330

Failure code [CA431] Idle validation switch error
SEN03941-01

Action code
Failure code
E01
CA431
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Idle validation switch error

Abnormality occurred in idle validation switch circuit

Operates at position of throttle of throttle sensor.
The input state (ON/OFF) from the idle validation switch 1 can be checked with the monitoring function (Code: ENGINE, 18300, IVS 1).
Causes

PD1

(Internal trouble)
Signal name
Between (5) and (4)
Signal 1
Between (6) and (4)
Signal 2
Voltage
See Fig. 1
Possible causes
and standard
value in normal
state

2

PD1 (female) (5)
Resistance
Max. 1 z

PD1 (female) (6)
Resistance
Max. 1 z

PD1 (female) (4)
Resistance
Max. 1 z

PD2 (female) (1)
Resistance
Max. 1 z

PD2 (female) (2)
Resistance
Max. 1 z

40-330

(female) (11) EC2 (female) (PD1 and 2,
too, is disconnected.)
Resistance
Min.
100 kz
3 ness
(female) (1) EC2 (female) (PD1 and 2, too,
is disconnected.)
Resistance
Min.
100 kz
Between EC2 (female) (11) EC3 (female)

(3), (4) (PD1 and 2, too, is disconnected.)
Resistance
Min.
100 kz

(3), (4) (PD1 and 2, too, is disconnected.)
Resistance
Min.
100 kz

Causes
Possible causes
and standard
value in normal
state

connector
SEN03941-01

Possible causes
and standard
value in normal
state
Defective engine controller
EC2 (female)
Signal name
Between (11) and

(32)
Signal 1
Signal 2
Voltage
See Fig. 1
40-330
SEN03941-01

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

SEN03941-01
40-330
11

Failure code [CA432] Idle validation action error
SEN03941-01

Action code
Failure code
E03
CA432
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Idle validation action error

Signals from the idle validation switch and throttle sensor do not agree (they are contradictory)
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
the accelerator pedal is ON.
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).
Engine speed does not rise from low idle.
The input state from throttle position sensor can be checked with the monitoring function
(Code: ENGINE, 31701/31707, THROTTLE POS)
Causes

PD1
Signal name
Between (2) and (3)
APS sig.
Between (5) and (4)
IVS 1
Between (6) and (4)
IVS 2
1 Defective accelerator pedal

Possible causes
and standard
value in normal
state
Voltage
When
released
0.50
0.80 V
When
pressed
3.70
4.00 V
See Fig. 1
2
40-330
12

PD1 (female) (1)
Resistance
Max.
10 z

PD1 (female) (2)
Resistance
Max.
10 z
Wiring harness between EC2(female) (21)

PD2 (female) (1)
Resistance
Max.
10 z

Causes
SEN03941-01

too, is disconnected.)

(with another wiring harness) (female) (9) EC2 (female) (PD1 and 2, too,
is disconnected.)
Possible causes
and standard
value in normal
state

EC2 (female) (PD1 and 2, too, is disconnected.)

connector
Resistance
Min.
100 kz
Resistance
Min.
100 kz
Resistance
Min.
100 kz
EC2 (female)
Accelelator pedal
Between (11) and

(32)
Signal 1
Signal 2
Voltage
See Fig. 1
When released
0.50 0.80 V
When pressed
3.70 4.00 V
40-330
13
SEN03941-01

40-330
14

SEN03941-01
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)
40-330
15

Failure code [CA435] Engine oil pressure switch error
SEN03941-01
Failure code [CA435] Engine oil pressure switch error

Action code
Failure code
E01
CA435
Contents of
trouble
Action of
controller
Trouble
Engine oil pressure switch error

Abnormality occurred in engine oil pressure switch signal circuit.

None in particular.
Problem that
appears on
machine
Engine oil switch-based engine protection function does not function.

Engine oil pressure monitor does not indicate normally.
Related
information
Method of reproducing failure code: Starting switch ON or start engine
Causes

Defective engine oil pressure

OIL PRESSURE SWITCH (male)
switch
Between OIL PRESURE
SWITCH (male) and body

2
Possible causes
and standard
value in normal
state
Resistance
Max. 10 z

OIL PRESSURE SWITCH (female)
Resistance
Max. 10 z

ResisMin.
100 kz

connector
Connecting parts among engine oil pressure switch, engine wiring

EC1 (female)
Resistance
Max. 10 z
40-330
16

Failure code [CA441] Battery voltage low error
SEN03941-01

Action code
Failure code
E03
CA441
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Battery voltage low error

Low voltage (Max. 6 V) occurred in controller power supply voltage circuit.

Engine stops
Starting performance is poor
Causes
1
Loose, corroded battery terminal

Inspect battery terminal directly for loose and corrosion.
a Prepare with starting switch OFF, then turn starting switch OFF
and START and carry out troubleshooting.
2 Defective battery voltage

3
box FS1
Battery (1 piece)
Starting switch
Voltage
Between (+) and ()

terminals
OFF
Min. 12 V
START
Min. 6.2 V
If the fuse is burn, the circuit probably has a grounding fault, etc.
(See cause 6.)
L107 (Male)
Resistance

200 400 z
4 out relay (L107) (Internal dis- a Prepare with starting switch OFF, then turn starting switch ON
connection or short circuit)
Possible causes
and standard
value in normal
state
When engine control cut-out relay (L107) is replaced with a relay of

the same type, if the condition becomes normal, the engine control
cut-out relay (L107) is defective.
L108 (Male)
Resistance

200 400 z
6

Resistance
Max. 10 z

Resistance
Max. 10 z

(2) ground
Resistance
Max. 10 z
40-330
17

SEN03941-01
Causes

Ground fault in wiring harWiring harness between fuse No. 4 of fuse

7 ness
box FS1 L107, L108 (female) (3) and
(Contact with ground circuit) ground
L108 (female) (5) EC3 (3), (4) and ground
Resistance
Min.
100 kz
Resistance
Max. 10z

Wiring harness among pins between EC3
(female) (3), (4) EC3 (female) (1), (2)
(With battery terminal disconnected)
Possible causes
and standard
value in normal
state

(with another wiring harness) (female) (3), (4) EC2 (female)
(female) (1), (2) EC2 (female)

connector
Resistance
Min.
100 kz
Resistance
Min.
100 kz
Resistance
Min.
100 kz
Connecting parts among fuse No. 4 of fuse box FS1, engine unit
wiring harness, and engine controller are suspected. Inspect them
directly.
40-330
18
EC3 (female)
Starting switch
Voltage
Between (3), (4) and

(1), (2)
ON
Min. 24 V
START
Min. 12 V

SEN03941-01
40-330
19

Failure code [CA442] Battery voltage high error
SEN03941-01

Action code
Failure code
E03
CA442
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Battery voltage high error

High voltage (min. 36V) occurred in controller power supply voltage circuit.
Engine may stop.
Causes

Possible causes
and standard
value in normal
state
Battery
Voltage
Between (+) and () terminals
Less than 32 V
troubleshooting.
2 Defective alternator
E02 (male)
Engine speed
Voltage
Between (1) and

ground
Min. medium speed
27.5 29.5 V

40-330
20
EC3 (female)
Voltage
Between (3), (4) and (1), (2)
Less than 32 V

SEN03941-01
40-330
21

Failure code [CA449] Common rail pressure high error 2
SEN03941-01

Action code
Failure code
E03
CA449
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Common rail pressure high error 2

Voltage (2) in common rail circuit is abnormally high.

Limits output and continues operation (limits common rail pressure).
Engine sound becomes larger under no load or light load.
The input state (common rail pressure) from the common rail pressure sensor can be checked with
the monitoring function (Code: ENGINE, 36400, RAIL PRESS).
The input state (voltage) from the common rail pressure sensor can be checked with the monitoring
function (Code: ENGINE, 36402, RAIL PRESS).
Causes
Possible causes
and standard
value in normal
state
2 Air in low-pressure circuit
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 filter.
2) Operate the feed pump of the fuel pre-filter.
3) Inspect leakage of fuel and air from the pressure pickup plug.
Defective fuel return circuit

3
device
a For check of pressure in fuel return circuit, see Testing and

adjusting, Testing fuel pressure.
Fuel circuit pressure At low idle or cranking
Defective common rail pressure sensor
Monitoring code
(Machine monitor)
Code: 36400,
RAIL PRESS
5 Defective pressure limiter
6 Defective supply pump
Monitoring information
Condition when
engine stopped
0 0.39 MPa
{0 4 kg/cm2}
For testing of leakage from pressure limiter, see Testing and adjusting, Testing leakage from pressure limiter and return rate from
injector.
Leakage from pressure limiter
22
Max. 0.02 MPa

{Max. 0.19 kg/cm2}
a Prepare with starting switch ON, then carry out troubleshooting

without turning starting switch OFF.
4
40-330
At low idle
0 cc (No leakage)
If causes 1 5 are not detected, supply pump may be defective.

SEN03941-01
40-330
23

Failure code [CA451] Common rail pressure sensor high error
SEN03941-01

Action code
Failure code
E03
CA451
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Common rail pressure sensor high error

High voltage occurred in common rail pressure sensor.

Engine speed or output drops.
Causes
Defective sensor power sup- If failure code [CA227] is indicated simultaneously, carry out trouble1
ply 2 system
Defective common rail pres2
sure sensor
FUEL RAIL PRESS

Between (3) and (1)
Voltage
Power supply
4.75 5.25 V

Possible causes
and standard
value in normal
state

3 5V, 24V circuit) in wiring harWiring harness between EC1 (female) (25)
ness
Voltage Max. 1 V
FUEL RAIL PRESS (female) (2) and ground

4 ness
(with another wiring harness) FUEL RAIL PRESS (female) (2), EC1
(female) (37) FUEL RAIL PRESS (female)
(3)

connector
Resistance
Min.
100 kz
Connecting parts among common rail pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them
directly.
EC1
Between (37) and
(47)
40-330
24
Voltage
Power supply
4.75 5.25 V

SEN03941-01
40-330
25

Failure code [CA452] Common rail pressure sensor low error
SEN03941-01

Action code
Failure code
E03
CA452
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Common rail pressure sensor low error

Low voltage occurred in common rail pressure sensor.

Engine speed or output drops.
Causes
Defective sensor power sup- If failure code [CA187] is indicated simultaneously, carry out trouble1
ply 2 system
Defective common rail pres2
sure sensor
FUEL RAIL PRESS

Between (3) and (1)
Voltage
Power supply
4.75 5.25 V

Possible causes
and standard
value in normal
state

Ground fault in wiring harand carry out troubleshooting.
3 ness
ResisMin.
(Contact with ground circuit) Wiring harness between EC1 (female) (25)
FUEL RAIL PRESS (female) (2) and ground
tance
100 kz

4 ness
(with another wiring harness) FUEL RAIL PRESS (female) (2), EC1
(female) (37) FUEL RAIL PRESS (female)
(3)

connector
Resistance
Min.
100 kz
Connecting parts among common rail pressure sensor, engine wiring harness, and engine controller are suspected. Inspect them
directly.
EC1
Between (37) and
(47)
40-330
26
Voltage
Power supply
4.75 5.25 V

SEN03941-01
40-330
27

Failure code [CA488] Derating of torque by abnormally high charge temperature
SEN03941-01
Failure code [CA488] Derating of torque by abnormally high charge

temperature
Action code
Failure code
E03
CA488
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

The input state (boost temperature) from the boost pressure and temperature sensors can be
The input state (boost temperature sensor voltage) from the boost pressure and temperature sensors can be checked with the monitoring function (Code: ENGINE, 18501, CHG TEMP).
28
Inspect following directly.

Drop in cooling performance Malfunction of hydraulic drive fan
1
of aftercooler
Insufficient cooling air
Clogged aftercooler fin
2
Abnormally high temperature at turbocharger outlet
40-330
Derating of torque by abnormally high charge temperature

Temperature signal of boost pressure sensor and temperature sensor is above upper control limit.
Causes
Possible causes
and standard
value in normal
state
Inspect related parts directly.


SEN03941-01

Action code
Failure code
E03
CA553
Contents of
trouble
Trouble
Common rail pressure high error 1

Voltage (1) in common rail circuit is abnormally high.
Action of
controller
None in particular.
Problem that
appears on
machine
Engine sound becomes larger under no load or light load.

Related
information
Causes
Possible causes
and standard
value in normal
state

Defective connection of
ground terminal
Inspect following directly for connection of ground terminal.

Ground terminal (battery (-)) of machine main unit.
Ground terminal of engine
Ground terminal of engine controller
Ground terminal of starting motor
Broken O-ring of supply

pump actuator
Inspect O-ring directly for breakage.
40-330
29

Failure code [CA559] Supply pump pressure very low error
SEN03941-01

Action code
Failure code
E03
CA559
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Supply pump pressure very low error

No-pressure feed (1) occurred in common rail circuit.

Engine does not start or starting performance is poor
Causes
1 Fuel leakage to outside

Inspect for fuel leakage directly (visual inspection at engine low
idle).
a For check of pressure in fuel low-pressure circuit, see Testing and
adjusting, Testing fuel pressure.
Defective low-pressure cir2

cuit device
3 Defective pressure limiter
Pressure in fuel lowpressure circuit
0.3 1.1 MPa

{3.1 11.3 kg/cm2}
At low idle
(When starting is
available)
0.5 1.3 MPa

{5.1 13.3 kg/cm2}
For testing of leakage from pressure limiter, see Testing and adjusting, Testing leakage from pressure limiter and return rate from
injector.
Leakage from pressure limiter
Possible causes
and standard
value in normal
state
Cranking
(When starting is not
available)
At low idle
0 cc (No leakage)
a For testing of return rate from injector, see Testing and adjusting,
Testing leakage from pressure limiter and return rate from injector.
Defective injector
4 (High-pressure piping in
head included)
Return rate from

injector
Cranking
available)
Max. 90 cc/min.
At low idle
(When starting is
available)
Max. 180 cc/min.
a For testing of return rate from supply pump, see Testing and
adjusting, Testing leakage-from pressure limiter and return rate
from injector.
5 Defective supply pump
40-330
30
Cranking
available)
Return rate from supply pump
At low idle
(When starting is
available)
Max. 140 cc/min.
Max. 1,000 cc/min.

SEN03941-01
40-330
31

Failure code [CA689] Engine Ne speed sensor error
SEN03941-01

Action code
Failure code
E03
CA689
Trouble
Engine Ne speed sensor error

Contents of
trouble
Abnormality occurred in signals from engine Ne speed sensor.
Action of
controller

Problem that
appears on
machine
Related
information
There is hunting from engine.

Causes
1
Defective Ne speed sensor

power supply system

Defective engine Ne speed

sensor
CRANK SENSOR
Between (1) and (2)
Voltage
Power supply
4.75 5.25 V

Broken engine Ne speed
3 sensor or defective clearance
4
Possible causes
and standard
value in normal
state
Broken rotation sensing flywheel

5
Inspect engine Ne speed sensor for breakage or clearance.
Inspect it for breakage directly.

CRANK SENSOR (female) (3)
Resistance
Max.
10 z

6 ness
ResisMin.
CRANK SENSOR (female) (3) and ground
tance
100 kz
Hot short (Contact with 5V,
7
Voltage Max. 1 V
CRANK SENSOR (female) (3) and ground
Short circuit in wiring harCRANK SENSOR (female) (3), EC1 (female)
8 ness
(16) CRANK SENSOR (female) (1)
CRANK SENSOR (female) (3), EC1 (female)
(48) CRANK SENSOR (female) (2)
40-330
32
Resistance
Min.
100 kz
Resistance
Min.
100 kz

9
Possible causes
and standard
value in normal
state
SEN03941-01
Causes

connector
Connecting parts among engine Ne speed sensor, engine wiring

EC1
Between (16) and
(48)
Voltage
Power supply
4.75 5.25 V
40-330
33

Failure code [CA731] Engine Bkup speed sensor phase error
SEN03941-01
Failure code [CA731] Engine Bkup speed sensor phase error

Action code
Failure code
E03
CA731
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble

Engine does not start or is difficult to start.
Idle speed is unstable.
Broken engine Ne speed

sensor
Inspect engine Ne speed sensor for breakage directly.
Broken engine Bkup speed

sensor
Inspect engine Bkup speed sensor for breakage directly.

Inspect it for defect or breakage according to the following procedure.
1) Set No. 1 cylinder to compression top dead center (align stamping mark).
2) If tip of Ne speed sensor is aligned with center of oblong hole of
rotation sensing flywheel, it is mounted normally.
Inspect it for defect or breakage according to the following procedure.

1) Set No. 1 cylinder to compression top dead center (align stampDefective/broken mount of
ing mark).
4 rotation sensing ring on cam2) Remove Bkup speed sensor.
shaft side
3) If 2 grooves (1 thread) of rotation sensing ring can be seen
through sensor mounting hole, it is mounted normally.
5
34
Defective/broken mount of
3 rotation sensing flywheel on
crankshaft side
40-330
Engine Bkup speed sensor phase error

Abnormal phase is detected in signals of engine Ne speed sensor and engine Bkup speed sensor.
Causes
Possible causes
and standard
value in normal
state
Defective timing between

crankshaft and camshaft
Inspect crankshaft and camshaft for timing directly.
Defective connection of
ground terminal
Inspect following directly for connection of ground terminal.

Ground terminal (battery (-)) of machine main unit.
Ground terminal of engine
Ground terminal of engine controller
Ground terminal of starting motor

Failure code [CA757] All continuous data lost error
SEN03941-01

Action code
Failure code
E03
CA757
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
All continuous data lost error

All data in engine controller are lost.

Engine stops and sometimes cannot be started.
The monitoring function of the machine monitor (engine controller system) sometimes fail to work
normally.
Causes
2
Loose, corroded battery terminal

Inspect battery terminal directly for loose and corrosion.
with starting switch OFF and START.

box FS1
Battery (1 piece)
Starting switch
Voltage
Between (+) () terminals
OFF
Min. 12 V
START
Min. 6.2 V
If the fuse is broken, the circuit probably has a grounding fault, etc.
L107 (male)
Possible causes
and standard
value in normal
state
Resistance

200 400 z
L108 (male)
Resistance

200 400 z
7

Resistance
Max. 10z

Resistance
Max. 10z

(2) ground
Resistance
Max. 10z
40-330
35

SEN03941-01
Causes
8
Possible causes
and standard
value in normal
state

connector

Connecting parts among fuse No. 4 of fuse box FS1, engine unit
wiring harness, and engine controller are suspected. Inspect them
directly.
EC3 (female)
Between (3) and (1)
40-330
36
Starting switch
Voltage
ON
Min. 24 V
START
Min. 12 V

SEN03941-01
40-330
37

Failure code [CA778] Engine Bkup speed sensor error
SEN03941-01

Action code
Failure code
E03
CA778
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Engine Bkup speed sensor error

Abnormality is detected in signals of engine Bkup speed sensor.

Controls Bkup speed sensor with signals of Ne speed sensor.
Causes
1
Defective engine Bkup

speed sensor
CAM SENSOR
Between (1) and (2)
Voltage
Power supply
4.75 5.25 V

Broken engine Bkup speed
3 sensor or defective clearance
Inspect engine Bkup speed sensor directly for breakage or clearance.
4 Broken rotation sensing ring Inspect it for breakage directly.

Possible causes
and standard
value in normal
state

5

CAM SENSOR (female) (3)
Resistance
Max.
10 z

6 ness
Wiring
ResisMin.
CAM SENSOR (female) (3) and ground
tance
100 kz
7
Voltage Max. 1 V
CAM SENSOR (female) (3) and ground
Short circuit in wiring harCAM SENSOR (female) (3), EC1 (female)
8 ness
(37) CAM SENSOR (female) (1)
CAM SENSOR (female) (3), EC1 (female)
(47) CAM SENSOR (female) (2)
40-330
38
Resistance
Min.
100 kz
Resistance
Min.
100 kz

9
Possible causes
and standard
value in normal
state
SEN03941-01
Causes

connector
Connecting parts among engine Bkup speed sensor, engine wiring

EC1
Between (37) and
(47)
Voltage
Power supply
4.75 5.25 V
40-330
39

Failure code [CA1633] KOMNET datalink timeout error
SEN03941-01

Action code
Failure code
E03
CA1633
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
KOMNET datalink timeout error

Engine controller detected a communication error in the KOMNET communication circuit used for the
communication between the HST controller and machine monitor.
Continues the operation from the default mode.
KOMNET communication information may not be transmitted correctly to cause incorrect operation
of machine. (Problem depends on failure occurrence location.)
If failure code [DAJRKR] is indicated simultaneously, carry out troubleshooting for it first.
Causes

Defective CAN end point

resistance

2
40
Resistance
Between (A) and (B)
110 140 z

CAN2 (male)
Resistance
Between (A) and (B)
110 140 z

Possible causes
and standard
value in normal
state
40-330
CAN1 (male)

(47) HST (female) (28), (38)
Resistance
Max. 1 z

(47) L29 (female) (3), (8)
Resistance
Max. 1 z

(47) C140 (female) (28), (38)
Resistance
Max. 1 z

(47) L80 (female) (7), (8)
Resistance
Max. 1 z

(47) CAN1 (female) (A), (B)
Resistance
Max. 1 z

Resistance
Max. 1 z

Causes
SEN03941-01

Possible causes
and standard
value in normal
state

(47) HST (female) (28), (38) and ground
Resistance
Min. 1 Mz

(47) L29 (female) (3), (8) and ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

(47) CAN1 (female) (A), (B) and ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

3
(Short circuit with ground cir- (47) C140 (female) (28), (38) and ground
cuit)
Defective machine monitor,

4 HST controller, engine controller or KOMTRAX terminal
a If above troubleshootings 1 3 have not identified the cause of

the trouble, failure on the machine monitor, HST controller,
engine controller or KOMTRAX terminal should be suspected.
(Since trouble is in system, troubleshooting cannot be carried
out.)
40-330
41
SEN03941-01

40-330
42

SEN03941-01
40-330
43

Failure code [CA2185] Throttle sensor supply voltage high error
SEN03941-01

Action code
Failure code
E03
CA2185
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Throttle sensor supply voltage high error

High voltage (min. 5.25V) occurred in throttle sensor power supply circuit.
Causes

Possible causes
and standard
value in normal
state
1 ness
(with another wiring harness) too, is disconnected.)
(3) (PD1 and 2, too, is disconnected.)
44
Min.
100 kz
Resistance
Min.
100 kz

connector
Connecting parts among accelerator pedal dial, engine unit wiring


40-330
Resistance

SEN03941-01
40-330
45

Failure code [CA2186] Throttle sensor power supply low error
SEN03941-01

Action code
Failure code
E03
CA2186
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Throttle sensor power supply voltage low error

Low voltage occurred in throttle sensor power supply circuit.

Causes

1 ness
ResisMin.
tance
100 kz
Possible causes
and standard
value in normal
state

ResisMin.
(with another wiring harness) (female) (9) EC2 (female) (PD1 and 2, too,
tance
100 kz
is disconnected.)

connector

40-330
46

SEN03941-01
40-330
47

Failure code [CA2249] Supply pump pressure very low error 2
SEN03941-01

Action code
Failure code
E03
CA2249
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
40-330
48
Trouble
Supply pump pressure very low error 2

No-pressure feed (2) occurred in common rail circuit.

Causes
1

Carry out troubleshooting for failure code [CA559].

SEN03941-01
40-330
49

Failure code [CA2311] Abnormality in IMV (IMA) solenoid
SEN03941-01

Action code
Failure code
E03
CA2311
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Abnormality in IMV (IMA) solenoid

Resistance in supply pump actuator circuit is abnormally high or low.

Causes

Defective supply pump actu- CP3 PUMP REGULATOR (male)

ator
Between (1) and (2)
Resistance
Max. 5 z

3
Possible causes
and standard
value in normal
state
Min. 100 kz

Resistance
Max. 5 z

Resistance
Max. 5 z

Ground fault in wiring har4 ness
ResisMin.
(Contact with ground circuit) CP3 PUMP REGULATOR (female) (1) and
tance
100 kz
ground

connector
40-330
50
EC1 (female)
Resistance
Max. 5 z
Min. 100 kz

SEN03941-01
40-330
51

Failure code [CA2555] Intake heater relay disconnection error
SEN03941-01

Action code
Failure code
E01
CA2555
Contents of
trouble
Action of
controller
Trouble
Intake heater relay disconnection error

There is disconnection in intake air heater relay.

None in particular.
Problem that
appears on
machine
Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temperature)
Related
information
The input state (boost temperature) can be checked with the monitoring function (Code: ENGINE,
18500, CHG TEMP)
Method of reproducing failure code: Turn the starting switch ON when boost temperature is 4C or
less.
Causes

without turning starting switch ON. (Test relay unit).
Defective heater relay

Resistance
Between E06 and ground
300 600 z

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.
Possible causes
and standard
value in normal
state

2

E06
Resistance
Max.
10 z
Wiring harness between heater relay R90

R20
Resistance
Max.
10 z

ResisMin.
(with another wiring harness) (female) (40) EC2 (female) (E06, too, is
tance
100 kz
disconnected.)

connector
Connecting parts among heater relay, engine unit wiring harness,

40-330
52
EC2 (female)
Resistance
300 600 z

SEN03941-01
40-330
53

Failure code [CA2556] Intake heater relay short circuit error
SEN03941-01

Action code
Failure code
E01
CA2556
Contents of
trouble
Action of
controller
Trouble
Intake heater relay short circuit error

There is short circuit in intake air heater relay.

None in particular.
Problem that
appears on
machine
Intake air heater does not function. (Poor starting performance, white exhaust smoke at low temperature)
Related
information
The input state (boost temperature) can be checked with the monitoring function (Code: ENGINE,
18500, CHG TEMP)
Method of reproducing failure code: Turn the starting switch ON when boost temperature is 4C or
less.
Causes

without turning starting switch ON. (Test relay unit).

Between E06 and ground
Resistance
300 600 z

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.
Possible causes
and standard
value in normal
state

2 ness
ResisMin.
E06
tance
100 kz
ResisMin.
(with another wiring harness) (female) (40) EC2 (female) (E06, too, is
tance
100 kz
disconnected.)

connector
Connecting parts among heater relay, engine unit wiring harness,

40-330
54
EC2 (female)
Resistance
300 600 z

SEN03941-01
40-330
55
SEN03941-01

2009 KOMATSU
All Rights Reserved
40-330
56
SEN03942-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
40 Troubleshooting
40

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
40-340

Failure code [D160KY] Backup alarm/lamp relay 1 circuit: Hot short
SEN03942-01

Action code
Failure code
E01
D160KY
Contents of
trouble
Trouble
Backup alarm/lamp relay 1 circuit: Hot short

Since there is hot short in backup alarm/lamp relay 1 output system, backup lamp relay 1 does not
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.
Problem that
appears on
machine
Related
information
Backup lamp is kept ON.

Backup alarm is kept ON.
Alarm buzzer may not sound.
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.
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.
Causes

troubleshooting.
Condition becomes
Replace backup lamp normal.
relay (L109) with
Defective backup alarm/lamp another relay.
Condition does not
1
relay (L109) (Internal defect)
become normal.
Resistance
Between L109 (male) (1) (2)
Hot short (Contact with 5 V,

2 24 V circuit) in wiring harness
Relay (L109) is
normal

Possible causes
and standard
value in normal
state
40-340
Relay (L109) is
defective.
200 400
z

(Set FNR (directional) lever or switch to R (Reverse) position.)
Wiring harness between L24 (female) (12)
L109 (female) (2)
Voltage
Max. 1 V
If causes 1 and 2 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)

SEN03942-01
40-340

Failure code [D192KY] ECSS solenoid relay: Hot short
SEN03942-01

Action code
Failure code
E01
D192KY
Contents of
trouble
Trouble
ECSS solenoid relay: Hot short

Since there is hot short in ECSS solenoid relay output system, ECSS solenoid relay does not operate.
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
appears on
machine
Related
information
ECSS does not operate.

Backup alarm/lamp may not sound.
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.
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.
Causes

troubleshooting.
Condition becomes
Replace ECSS sole- normal.
noid relay (L110) with
Defective ECSS solenoid
Condition does not
another relay.
1
become normal.
Resistance

Relay (L110) is
normal.

Possible causes
and standard
value in normal
state
40-340
Relay (L110) is
defective.
200 400
z

Between wiring harness L24 (female) (11)
L110 (female) (2) and ground
Voltage
Max. 1 V
If causes 1 and 2 are not detected, machine monitor may be defective. (Since trouble is in system, troubleshooting cannot be carried
out.)

SEN03942-01
40-340

Failure code [D1B0KA] HST safety relay: Disconnection
SEN03942-01

Action code
Failure code
E03
D1B0KA
Contents of
trouble
Related
information
HST safety relay: Disconnection

(HST controller system)
Disconnection was detected in HST safety relay circuit when starting switch is turned ON.
Action of
machine monitor
Problem that
appears on
machine
Trouble
Turns clutch EPC solenoid output OFF.

Turns motor 1 solenoid output OFF.
Turns HST safety relay output OFF.
Even if trouble disappears, system does not reset itself until starting switch is turned OFF.
Traction force decreases.

Travel speed is not limited with speed range selector switch and travel speed control dial.
If engine is stopped without applying parking brake securely on slope, machine moves down suddenly.
If [DAJ2L3] or [DAJ2L4] is displayed, carry out troubleshooting for it first.
Following output command values can be checked with monitoring function.
Motor 1 solenoid output: HST 80000 MOTOR SOL DIR (mA)
HST safety relay output: HST 40979 D_OUT_15 (ON/OFF)
Clutch EPC solenoid output: HST 80100 CLUTCH SOL DIR (mA)
Causes

troubleshooting.
Defective HST safety relay

(Internal defect)
Replace HST safety

relay (L111) with
another relay.
Condition becomes
normal.
Relay (L111) is
defective.
Condition does not

become normal.
Relay (L111) is
normal.

Resistance
200 400
z
troubleshooting.
Possible causes
and standard
value in normal
state
Defective VIS power supply

2 holding relay (Internal short
circuit)
Replace VIS power

supply holding relay
(L102) with another
relay.
Condition becomes
normal.
Relay (L102) is
defective.
Condition does not

become normal.
Relay (L102) is
normal.

Resistance
200 400
z

Disconnection in wiring harness (Disconnection in wiring
3
or defective contact in connector)
Wiring harness between HST (female) (17)

L111 (female) (2)
Resistance
Max. 1 z

L111 (female) (1)
Resistance
Max. 1 z
Wiring harness between fuse FS1 (No. 3)

L102 (female) (5)
Resistance
Max. 1 z

4 Defective HST controller
40-340
HST
Voltage
Between (17) ground
Max. 1 V

SEN03942-01
40-340

Failure code [D1B0KB] HST safety relay: Ground fault
SEN03942-01

Action code
Failure code
E01
D1B0KB
Contents of
trouble
Related
information
HST safety relay: Ground fault

Ground fault was detected in HST safety relay circuit when starting switch is turned ON.
Action of
machine monitor
Problem that
appears on
machine
Trouble


Clutch EPC solenoid output: HST 80100 CLUTCH SOL DIR (mA).
Causes

troubleshooting.

(Internal defect)
Possible causes
and standard
value in normal
state
Replace HST safety

relay (L111) with
another relay.
Condition becomes
normal.
Relay (L111) is
defective.
Condition does not

become normal.
Relay (L111) is
normal.

Resistance
200 400
z

2 ness (Contact with GND cirBetween
wiring harness (HST (female) (17)
Resiscuit)
Min. 1 Mz
tance
40-340
If causes 1 and 2 are not detected, HST controller may be defective.


SEN03942-01
40-340

Failure code [D1B0KY] HST safety relay: Hot short
SEN03942-01

Action code
Failure code
E03
D1B0KY
Contents of
trouble
Related
information
HST safety relay: Hot short

Hot short was detected in HST safety relay circuit.
Action of
machine monitor
Problem that
appears on
machine
Trouble


If [DAJ2L3] or [DAJ2L4] is displayed, carry out troubleshooting for it first.
Clutch EPC solenoid output: HST 80100 CLUTCH SOL DIR (mA).
Causes

troubleshooting.

(Internal defect)
Possible causes
and standard
value in normal
state
Relay (L111) is
defective.
Condition does not

become normal.
Relay (L111) is
normal.
Resistance
10
Condition becomes
normal.


40-340
Replace HST safety

relay (L111) with
another relay.
200 400
z

Between wiring harness HST (female) (17)
Voltage
Max. 1 V
If causes 1 and 2 are not detected, HST controller may be defective.


SEN03942-01
40-340
11

Failure code [D5ZHL6] IGN C system: Ground fault/Disconnection
SEN03942-01

Action code
Failure code
E01
D5ZHL6
Contents of
trouble
Trouble
IGN C system: Ground fault/Disconnection

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
is ON, there is not C terminal signal input.)
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
machine
Related
information
Engine cannot be started (It may be able to be started, depending on faulty part).
Input state (ON/OFF) from starting switch C terminal to machine monitor be checked with monitoring
function.
(MONITOR PANEL 40900 D-IN-2)
Method of reproducing failure code: Turn starting switch to START position.
Causes

a Prepare with starting switch OFF, then turn starting switch to ON/
OFF/START position and carry out troubleshooting.
Defective starting switch

(Internal defect)
L02
Between (3) ground
Starting switch
position
Voltage
START
20 30 V
OFF/ON
Max. 1 V

2
Possible causes
and standard
value in normal
state

L25 (female) (2)
Resistance
Max. 1 z

L79 (female) (3)
Resistance
Max. 1 z

L106 (female) (3)
Resistance
Max. 1 z

Ground fault in wiring harL79 (female) (3) and ground
3 ness (Contact with GND cirBetween wiring harness L79 (female) (6)
cuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn starting switch to ON/
OFF/START position and carry out troubleshooting.
L25
Between (2) ground
40-340
12
Starting switch
position
Voltage
START
20 30 V
OFF/ON
Max. 1 V

SEN03942-01
40-340
13

Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection
SEN03942-01
Failure code [DAF3KK] UNSW power supply: Ground fault/

Disconnection
Action code
Failure code
E01
DAF3KK
Contents of
trouble
Trouble
UNSW power supply: Ground fault/Disconnection

When accessory power supply (power supply for operation) voltage is above 17 V, UNSW power
supply (power supply for memory) has ground fault.
Action of
None in particular.
machine monitor
Problem that
appears on
machine
Related
information
Service meter time gains or loses.

Odometer does not advance.
Fault history data is not saved.
Method of reproducing failure code: Turn starting switch ON.
Causes

Possible causes
and standard
value in normal
state
Ground fault in wiring har1 ness (Contact with GND cirBetween wiring harness battery relay R01
cuit)
L24 (female) (4), (5) and ground
40-340
14
Resistance
Min. 1 Mz

Between L24 (female) (4), (5) (9), (10),
(17), (18), (19), (20)
Voltage
20 30 V

Failure code [DAF3KK] UNSW power supply: Ground fault/Disconnection
SEN03942-01
40-340
15

Failure code [DAFRKR] Machine monitor CAN-NET Signal: Disconnection
SEN03942-01

Action code
Failure code
E03
DAFRKR
Contents of
trouble
Trouble
Machine monitor CAN-NET Signal: Disconnection

HST controller cannot get information from machine monitor

Action of
Uses CAN information that was sent from machine monitor before the occurrence of the error.
machine monitor
Problem that
appears on
machine
Related
information
The monitor does not display normally
Causes


resistance

2
16
Resistance
Between (A) and (B)
110 140 z

CAN2 (male)
Resistance
Between (A) and (B)
110 140 z

Possible causes
and standard
value in normal
state
40-340
CAN1 (male)
Wiring harness between HST (female) (28),

(38) L80 (female) (7), (8)
Resistance
Max. 1 z

(38) L29 (female) (3), (8)
Resistance
Max. 1 z

(38) EC2 (female) (46), (47)
Resistance
Max. 1 z

(38) C140 (female) (28), (38)
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z

Causes
SEN03942-01

Possible causes
and standard
value in normal
state

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Grounding fault in wiring harWiring harness between HST (female) (28),

3 ness (Contact with ground
(38) EC2 (female) (46), (47) and ground
circuit)
(38) C140 (female) (28), (38) and ground
Defective power supply circuit of machine monitor

a Power supply circuit or grounding circuit may be defective.

Confirm that there is no disconnection of the circuit or defective
mating of the connector.
out.)
40-340
17
SEN03942-01

40-340
18

SEN03942-01
40-340
19

Failure code [DAJ0KK] HST controller power supply: Low voltage
SEN03942-01

Action code
Failure code
E03
DAJ0KK
Contents of
trouble
Trouble
HST controller power supply: Low voltage

Low voltage was detected in HST controller power supply.

(While engine was running and alternator voltage was above 20 V, controller voltage was below 18
V.)
Turns all outputs OFF.

Action of
Trouble which may be detected wrongly is not detected.
machine monitor
Problem that
appears on
machine
Related
information
Machine cannot travel (in either direction).

Another trouble may be detected.
If gear is set in neutral and engine is restarted while controller voltage is above 20 V, system is reset.
Method of reproducing failure code: Turn starting switch ON
Causes
1 Defective (Broken) fuse

Check fuse FS1 (No. 3) directly.
Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between HST (female) (1)
2
or defective contact in con- fuse FS1 (No. 3)
nector)
fuse FS1 (No. 3)
Resistance
Max. 1 z
Resistance
Max. 1 z

40-340
20
HST
Voltage
Between (1), (11) ground
20 30 V

SEN03942-01
40-340
21

Failure code [DAJ0KT] HST controller memory (EEPROM): Abnormality
SEN03942-01

Action code
Failure code
E01
DAJ0KT
Contents of
trouble
Trouble
HST controller memory (EEPROM): Abnormality

Information in HST controller ROM (non-volatile memory) is abnormal.
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
machine
Related
information
Performance may lower. For example, shift-down feel from 3rd or 4th gear speed may become bad.
Causes
Possible causes
and standard
value in normal
state
40-340
22

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.
3. Wait for at least 30 seconds, then turn starting switch ON again.
4. At this time, check that set information is reflected.
(Example: See if HST selection is kept at B and value is returned
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.

SEN03942-01
40-340
23

Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault
SEN03942-01
Failure code [DAJ1L4] HST controller main power line: Disconnection/

Ground fault
Action code
Failure code
E01
DAJ1L4
Contents of
trouble
Trouble
HST controller main power line: Disconnection/Ground fault

Low voltage was detected in HST controller main power line (battery relay drive voltage system).
Action of
Starts starting key OFF processing earlier.
machine monitor
Problem that
appears on
machine
Machine is not affected in particular.
Related
information
Causes
Possible causes
and standard
value in normal
state

40-340
24
Disconnection in wiring har- a Prepare with starting switch OFF, then carry out troubleshooting
ness (Disconnection in wiring
1
or defective contact in con- Wiring harness between HST (female) (13)
ResisMax. 1 z
nector)
D09 (female) (1), D10 (female) (1)
tance
HST (female)
Voltage
Between (13) ground
20 30 V

Failure code [DAJ1L4] HST controller main power line: Disconnection/Ground fault
SEN03942-01
40-340
25

Failure code [DAJ1L6] HST controller main power line: Hot short
SEN03942-01
Action code
Failure code
E01
DAJ1L6
Contents of
trouble
Action of
machine monitor
Problem that
appears on
machine
Related
information
Trouble
HST controller main power line: Hot short

Hot short was detected in HST controller main power line (battery relay drive voltage system).
Continues key OFF processing on assumption that battery relay is turned OFF.
(Turns controller self-holding circuit OFF on assumption that alternator L signal voltage system is
turned OFF.)
Displays error next time when starting switch is turned ON.
Battery voltage may lower earlier.
After error is detected, it is displayed next time when starting switch is turned ON.
Causes

Possible causes
and standard
value in normal
state


D09 (female) (1), circuit branch end and
ground
Voltage
Max. 1 V

ground
Voltage
Max. 1 V

ground
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn starting switch ON to

OFF and carry out troubleshooting.
40-340
26
HST (female)
Voltage
Between (13) ground
Max. 1 V

SEN03942-01
40-340
27

Failure code [DAJ2KK] Controller solenoid power supply: Low voltage
SEN03942-01

Action code
Failure code
E03
DAJ2KK
Contents of
trouble
Trouble
Controller solenoid power supply: Low voltage

Low voltage was detected in controller solenoid power supply system.

(While VIS power supply self-holding relay is ON and battery voltage is above 20 V, solenoid power
supply voltage below 18 V was detected.)
Action of
Turns all outputs OFF.
machine monitor
Problem that
appears on
machine
Related
information
Machine cannot travel.

Another failure may not be detected.
If gear is set in neutral and engine is restarted while solenoid voltage is above 19 V, system is reset.
Causes

Replace VIS power
(L102) with another
relay.
Condition becomes
normal.
Relay (L102) is
defective.
Condition does not

Relay (L102) is
become normal.
normal.
1
holding relay (Internal defect) a Prepare with starting switch OFF, then check unit.
When 24 V is applied
between (1) (2)
Possible causes
and standard
value in normal
state
Between terminals of
L102 (male) (3) (5) When no voltage is
applied between (1)
(2)
Resistance
Max. 1 z
Resistance
Min. 1 Mz
2
ResisMax. 1 z
nector)
L102 (female) (3)
tance
40-340
28

fuse FS1 (No. 3)
Resistance
HST
Voltage
Between (30) ground
20 30 V
Max. 1 z

SEN03942-01
40-340
29
SEN03942-01

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:
Action code
E01
Contents of
trouble
Failure code
DAJ2L3
Trouble
HST controller load power supply holding line: Hot short in wiring
harness
Hot short was detected in HST controller load power supply holding line.
(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
appears on
machine
If starting switch is turned OFF without applying parking brake securely on slope, machine moves
down suddenly.
If starting switch is turned OFF while fan is rotating in reverse, peak pressure may occur.
Related
information
Causes

Replace VIS power

Defective VIS power supply (L102) with another
1
holding relay (Internal defect) relay.
Condition becomes
normal.
Relay (L102) is
defective.
Condition does not

become normal.
Relay (L102) is
normal.

Possible causes
and standard
value in normal
state
Resistance

200 400
z

Voltage
Max. 1 V

40-340
30
HST
Voltage
Between (7) ground
Max. 1 V

Failure code [DAJ2L3] HST controller load power supply holding line: Hot short in wiring harness
SEN03942-01
40-340
31

Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault
SEN03942-01
Failure code [DAJ2L4] HST controller load power supply holding line:
Action code
Failure code
E01
Contents of
trouble
DAJ2L4
Trouble
HST controller load power supply holding line: Disconnection/

Ground fault
Disconnection or ground fault was detected in load power supply holding line during HST controller
final check.
(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
Problem that
appears on
machine
While there is disconnection, when starting switch is turned OFF, parking brake check cannot be
controlled and machine moves down.
If starting switch is turned OFF while disconnection is made or fan is rotating in reverse, peak pressure may occur.
Related
information
Causes

and OFF, wait for 30 seconds, and turn it ON again and carry out
troubleshooting.

(Internal defect)
Replace VIS power

(L102) with another
relay.
Condition becomes
normal.
Relay (L102) is
defective.
Condition does not

become normal.
Relay (L102) is
normal.

Resistance

Possible causes
and standard
value in normal
state
200 400
z

2
nector)
fuse FS1 (No.3)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

3 ness (Contact with GND cirBetween wiring harness HST (female) (7)
Resiscuit)
Min. 1 Mz
tance
40-340
32
HST
Voltage
Between (7) ground
Max. 1 V

Failure code [DAJ2L4] HST controller load power supply holding line: Disconnection/Ground fault
SEN03942-01
40-340
33

Failure code [DAJ5KX] Sensor 5V power supply: Out of output range
SEN03942-01

Action code
Failure code
E03
DAJ5KX
Contents of
trouble
Trouble
Sensor 5 V power supply: Out of output range

Sensor 5 V power supply of HST controller is below 4.7 V or above 5.3 V.
Action of
machine monitor Even if cause of failure disappears, system does not reset itself until engine is started again.
Problem that
appears on
machine
Related
information
If this trouble occurs during travel, travel speed may not increase or traction force may be insufficient.
Once machine stops, maximum travel speed is about 4 km/h.
If there is disconnection or ground fault, [DHH1KX], [DDD7KX] or [DF10KA] is displayed, too.
If there is hot short, [DHH1KY], [DDD7KY] or [DF10KB] is displayed, too.
If this failure occurs during travel, [DLT4KX] or [DLT3KX] may be displayed, too.
Causes

Defective travel speed control dial, defective speed

range selector switch, defec1
tive resistor, defective travel
speed sensor, or defective
HST pressure sensor
Possible causes
and standard
value in normal
state
code [DAJ5KX] lights
up (reset is indicated)
when a device is disconnected, that device
has trouble in it.
Travel speed control

dial
L54
Speed range selector

switch
L03
Resistor
L70
Travel speed sensor
T09
HST pressure sensor
T11

Ground fault in wiring har2 ness (Contact with GND cir- Between wiring harness HST (female) (22)
L54 (female) (A) or L70 (female) (2), (4) or
cuit)
T09 (female) (1) or T11 (female) (B) and
ground

Resistance
Min. 1 Mz
troubleshooting.
L54 (female) (A) or L70 (female) (2), (4) or
T09 (female) (1) or T11 (female) (B) and
ground
Voltage
Max. 1 V

40-340
34
HST
Voltage
Between (22) (32)
4.7 5.3 V

SEN03942-01
40-340
35

Failure code [DAJ9KQ] HST controller model selection: Disagreement of model selection signals
SEN03942-01
Failure code [DAJ9KQ] HST controller model selection: Disagreement

of model selection signals
Action code
Failure code
E03
DAJ9KQ
Contents of
trouble
Trouble
HST controller model selection: Disagreement of model selection

signals (Machine monitor system)
The HST controller model is mistaken for another one.
Action of
machine monitor
Operates on the assumption that the controller model which has been used before occurrence of the
failure code is still used.
Does not display failure codes which may be false detected.
Problem that
appears on
machine
After HST controller or machine monitor is replaced, if model is not selected, this failure code is displayed.
Continuing the travel in this condition may damage the HST.
Related
information
If the model selection is not done correctly after the HST controller or machine monitor is replaced,
this code is displayed.
Causes
Possible causes
and standard
value in normal
state
40-340
36
Improper machine monitor

model selection
Set the model using the adjustment function of the service mode of
the machine monitor (See Special functions of machine monitor
(EMMS) in Testing and adjusting)
HST controller part number

error
Confirm the part number of the HST controller. It must be replaced if

it is not the specified controller.

Failure code [DAJRKR] HST controller CAN-NET signal: Disconnection
SEN03942-01

Action code
Failure code
E03
DAJRKR
Contents of
trouble
Trouble
HST controller CAN-NET signal: Disconnection

Machine monitor cannot get information from HST controller
Uses CAN information that was sent from HST controller before the occurrence of the error.
Action of
machine monitor
Problem that
appears on
machine
Related
information

If HST controller power supply circuit is defective, machine cannot travel in either direction.
Causes


resistance
CAN1 (male)
Resistance
Between (A) and (B)
110 140 z

CAN2 (male)
Resistance
Between (A) and (B)
110 140 z

Possible causes
and standard
value in normal
state
2

(38) L80 (female) (7), (8)
Resistance
Max. 1 z

(38) L29 (female) (3), (8)
Resistance
Max. 1 z

(38) EC2 (female) (46), (47)
Resistance
Max. 1 z

(38) C140 (female) (28), (38)
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z
40-340
37

SEN03942-01
Causes

Possible causes
and standard
value in normal
state
40-340
38

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Grounding fault in wiring harWiring harness between HST (female) (28),

3 ness
(38) EC2 (female) (46), (47) and ground
a Carry out troubleshooting in "When HST controller power supply

circuit is defective" described later.


out.)

SEN03942-01
40-340
39

SEN03942-01
When HST controller power supply circuit is defective

Causes
a
Broken fuse box FS1 fuse

No. 3

If fuse is broken, circuit probably has ground fault etc. (See cause c.)
b
or defective contact in con- Wiring harness between fuse box FS1 fuse
ResisMax. 1 z
nector)
No. 3 HST (female) (1) (11).
tance
Between wiring harness fuse box FS1 fuse
No. 3 HST (female) (1) (11), branch end
and ground
Resistance
Min. 1 Mz

branch end and ground
Resistance
Min. 1 Mz

D07 (female) (1), T07 (3) and ground
Resistance
Min. 1 Mz

D08 (female) (1), T07 (1) and ground
Ground fault in wiring harc ness (Contact with GND cir- Between wiring harness L104 (female) (5)
cuit)
R59 (female) (1) and ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Between wiring harness L63 (female) (5), (1)

HST (female) (25) and ground
Resistance
Min. 1 Mz
Between wiring harness L15 (female) (3),

D01 (female) (5) HST (female) (5) and
ground
Resistance
Min. 1 Mz

HST (female) (34) and ground
Resistance
Min. 1 Mz

L126 (female) (1), HST (female) (15) and
ground
Resistance
Min. 1 Mz
Possible causes
and standard
value in normal
state

L101 (male)
Resistance
Between (5) (6)
200 400 z
a Prepare with starting switch OFF.

a Test relay unit.
Defective directional presd sure selector relay (L101)
Directional pressure
selector relay (L101)
Between (3) (5)
(1) (2)
Resistance
(relay is "ON")
Max. 1 z
Other than above

(relay is "OFF")
Min. 1 Mz
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

Causes
SEN03942-01

L126 (male)
Resistance
Between (1) (2)
200 400 z

a Test relay unit.
Defective backup alarm/lamp
e relay (L126) (Internal short
circuit)
Backup alarm/lamp
relay (L126)
Between (3) (5)
(1) (2)
Resistance
(relay is "ON")
Max. 1 z
Other than above

(relay is "OFF")
Min. 1 Mz

Possible causes
and standard
value in normal
state
Replace backup alarm/lamp relay (L126) with another relay. If condition becomes normal, backup alarm/lamp relay is defective.

Defective directional preswithout turning starting switch ON.
sure selector solenoid (InterResisnal short circuit)
Between T07 (male) (3) T07 (male) (4)
20 30 z
tance
Defective motor 2 solenoid

g
Defective fan reverse soleh

noid (Internal short circuit)

Resistance
20 30 z

Between R59 (male) (1) R59 (male) (2)
Resistance
35 45 z

i
Defective HST controller
HST
Voltage
20 30 V
40-340
41
SEN03942-01

Related circuit diagram (When HST controller power supply circuit is defective)
40-340
42

Failure code [DAJRMA] HST controller: Disagreement in option selection
SEN03942-01
Failure code [DAJRMA] HST controller: Disagreement in option

selection
Action code
Failure code
E03
DAJRMA
Contents of
trouble
Trouble
HST controller: Disagreement in option selection

Disagreement between the option setting done by the machine monitor and the option recognition by
done the HST controller.
Action of
The HST controller follows the option setting being recognized by itself.
Problem that
appears on
machine
After HST controller or machine monitor is replaced, if option is not set, this failure code is displayed.
The option setting does not work normally.
Related
information
If the option setting is not done correctly after the HST controller or machine monitor is replaced, this
code is displayed.
Causes
Possible causes
and standard
value in normal
state
1 Defective option setting
Set the option setting using the option select function of the
machine monitor (See Special functions of machine monitor
(EMMS) in Testing and adjusting)
The machine monitor may be defective. (Since trouble is in system,

troubleshooting cannot be carried out.)
The HST controller may be defective. (Since trouble is in system,

troubleshooting cannot be carried out.)
40-340
43
SEN03942-01

2009 KOMATSU
All Rights Reserved
40-340
44
SEN03943-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
40 Troubleshooting
40

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 [DDK3KA] Directional selector switch: Disconnection/Hot short .............................................. 28
Failure code [DDK3KB] Directional selector switch: Ground fault ................................................................ 30
Failure code [DDK6KA] FNR lever: Disconnection/Ground fault .................................................................. 32
Failure code [DDK6KY] FNR lever: Hot short ............................................................................................... 36
Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering) ............................... 38
40-350

Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in signal line
SEN03943-01
Failure code [DB2RKR] Engine controller CAN-NET: Disconnection in

signal line
Action code
Failure code
E03
DB2RKR
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Engine controller CAN-NET: Disconnection in signal line

Communication via CAN signal line between the HST controller and engine controller is defective.
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.
Once engine stops, recognized operating degree of accelerator is fixed to 0%.

If engine controller power supply circuit is defective, engine stops.
Causes


resistance

2
Resistance
Between (A) (B)
110 140 z

CAN2 (male)
Resistance
Between (A) (B)
110 140 z

Possible causes
and standard
value in normal
state
40-350
CAN1 (male)

(47) HST (female) (28), (38)
Resistance
Max. 1 z

(47) L80 (female) (7), (8)
Resistance
Max. 1 z

(47) L29 (female) (3), (8)
Resistance
Max. 1 z

(47) C140 (female) (28), (38)
Resistance
Max. 1 z

Resistance
Max. 1 z

Resistance
Max. 1 z

Causes
SEN03943-01

Possible causes
and standard
value in normal
state

(47) HST (female) (28), (38) and ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Grounding fault in wiring harWiring harness between EC2 (female) (46),

3 ness
Defective power supply circuit of engine controller

Carry out troubleshooting for "When engine controller power supply is defective" described later.
out.)
40-350
SEN03943-01

40-350

SEN03943-01
40-350

SEN03943-01
When engine controller power supply circuit is defective

Causes
a
Defective fuse No. 4 in fuse

box FS1 or No. 15 in FS2

If fuse box is damaged, circuit probably has ground fault etc.
(See cause c.)
Wiring harness between fuse box FS1, No. 4
fuse L107 (female) (3), L108 (female) (3)
Resistance
Max. 1 z

Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

L108 (female) (2) EC2 (female) (33)
Resistance
Max. 1 z

EC2 (female) (39)
Resistance
Max. 1 z
Disconnection in wiring harness (Disconnection in wiring Wiring harness between EC3 (female) (1),
b
or defective contact in con- (2) ground
nector)
L107 (female) (1), L108 (female) (1)

Possible causes
and standard
value in normal
state
Between wiring harness fuse box FS1, No. 4

fuse L107 (female) (3), L108 (female) (3)
and ground
Resistance
Min. 1 Mz
Ground fault in wiring harBetween wiring harness L107 (female) (5),

c ness (Contact with GND cir- L108 (female) (5) EC3 (female) (3), (4) and
cuit)
ground
Resistance
Min. 1 Mz

L107 (female) (1), L108 (female) (1) and
ground
Resistance
Min. 1 Mz

EC2 (female) (39) and ground
Resistance
Min. 1 Mz

L107, L108 (male)
Resistance
Between (1) (2)
200 400 z

a Check relay unit.
Defective engine controller
d cut relay (L107, L108) (Internal defect)
Engine controller cut

relay (L107, L108)
Between (3) (5)
(1) (2)
Resistance
(relay is "ON")
Max. 1 z
Other than above

(relay is "OFF")
Min. 1 Mz

Replace engine controller cut relay (L107, L108) with another relay.
If condition becomes normal, engine controller cut relay is defective.
40-350

Causes
SEN03943-01

Possible causes
and standard
value in normal
state
e Defective engine controller
EC2
Voltage
Between (33) ground
Max. 1 V
Between (39) ground
20 30 V
EC3
Voltage
20 30 V
Max. 1 V
Related circuit diagram (When engine controller power supply circuit is defective)
40-350

Failure code [DD1NL4] Fan automatic reverse switch signal: Abnormality
SEN03943-01

Action code
Failure code
E01
DD1NL4
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan automatic reverse switch signal: Abnormality

Because of hot short in fan automatic reverse switch system, fan automatic reverse switch input and
fan manual reverse switch input were sensed simultaneously.
Turns automatic reverse switch function OFF.
After error is detected, fan does not reverse.
Automatic reverse switch LED lamp keeps lighting.
Input state from fan automatic reverse switch can be checked with monitoring function
(Code: HST 93400 FAN REVERSE SW) (Code: MONITOR PANEL 40901 D-IN-9).
Method of reproducing failure code: Turn starting switch ON and fan manual reverse switch ON.
Causes

Defective fan automatic

1 reverse switch (Internal short
circuit)
L69 (male)
Between (3), (4) (5)
Possible causes
and standard
value in normal
state

(Contact with 5 V, 24 V circuit)
Fan automatic reverse

switch
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz

(Carry out troubleshooting with automatic reverse switch OFF)
Voltage
Max. 1 V

L25 (male)
Between (14) and
ground
40-350
Fan automatic reverse

switch
Voltage
ON
20 30 V
OFF
Max. 1 V

SEN03943-01
40-350

Failure code [DD1NLD] Fan reverse switch signal: Abnormality
SEN03943-01

Action code
Failure code
E01
DD1NLD
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan reverse switch signal: Abnormality

Since the fan manual reverse switch system is shorted with the power source, the fan manual
reverse switch remains at ON position. (Continuation for 30 seconds determines fault)
None in particular.
Fan remains in the reverse rotation.

The input state (ON/OFF) from the fan manual reverse switch can be checked with the monitoring function
(Code: HST 93400 FAN REVERSE SW).
(Code: MONITOR PANEL 40900 D-IN-1).
Causes

Defective fan reverse switch

L69 (male)
Between
(5) (1), (16)
Possible causes
and standard
value in normal
state
Fan manual reverse

switch
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz

2
(Contact with 5 V, 24V circuit) Wiring harness between L25 (female) (10)
Voltage Max. 1 V
L25 (male)
Between (10) and
ground
40-350
10
Fan manual reverse

switch
Voltage
ON
20 30 V
OFF
Max. 1 V

SEN03943-01
40-350
11

Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short
SEN03943-01
Failure code [DDB6KA] Parking brake reminder signal: Disconnection/

Hot short
Action code
Failure code
E01
DDB6KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Parking brake reminder signal: Disconnection/Hot short

HST controller detected disagreement with parking brake reminder signal from machine monitor.
(While parking brake reminder signal of machine monitor was input (closed), there was not parking
brake reminder signal of HST controller (open).
While there was not input signal (open), signal was input to parking brake indicator signal (closed).
None in particular.
down suddenly.
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)
[Parking brake indicator signal] (Recognition by machine monitor)
[Parking brake signal: reminder (A)/indicator (B)] (HST controller recognition)
(Monitoring code: HST 99100 PARKING A/B)
Causes
Defective diode
(Internal defect)

(See Testing and adjusting, Test procedure for diode.)
Between D02 (male) (6) (2)
Continuity is secured
2
ResisMax. 1 z
nector)
L53 (female) (2)
tance
(Test with parking brake applied.)
Possible causes
and standard
value in normal
state
Ground fault in wiring har3 ness (Contact with GND cir- Between wiring harness HST (female) (16)
cuit)
D02 (female) (5) and ground
Between wiring harness L27 (female) (2),
(14) D02 (female) (8) and ground

24V circuit) in wiring harness
40-350
12
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz

(Test with parking brake released.)
Voltage
Max. 1 V
troubleshooting.
HST
Voltage
Between (6) ground
Max. 1 V
a Prepare with starting switch OFF, turn starting switch ON and

L27
Voltage
Between (2) (14) ground
20 30 V

Failure code [DDB6KA] Parking brake reminder signal: Disconnection/Hot short
SEN03943-01
40-350
13

Failure code [DDB6KB] Parking brake indicator signal: Ground fault
SEN03943-01

Action code
Failure code
E01
DDB6KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Parking brake indicator signal: Ground fault

While parking brake indicator signal of machine monitor was not input (open), there was input signal
(switch B was closed).
None in particular.
Since machine can travel forward and reverse while parking brake is applied, parking brake may be
damaged (Alarm buzzer sounds in this case, however).
Causes
Defective diode
1
(Internal defect)

2
or defective contact in con- Wiring harness between L27 (female) (1), (6)
ResisMax. 1 z
nector)
L47 (female) (2)
tance
Possible causes
and standard
value in normal
state

Ground fault in wiring har(Test with parking brake applied.)
3 ness (Contact with GND circuit)
ResisMin.
tance
1 Mz
40-350
14
troubleshooting.
HST
Voltage
Between (16) ground
20 30 V

L27
Voltage
Max. 1 V

SEN03943-01
40-350
15

(intermediate switch): Trouble
SEN03943-01
Failure code [DDB6KZ] Parking brake switch (bottom switch) or parking

brake reminder switch (intermediate switch): Trouble
Action code
Failure code
E03
DDB6KZ
Contents of
trouble
Trouble
Parking brake switch (bottom switch) or parking brake reminder

switch (intermediate switch): Trouble (Machine monitor system)
Parking brake indicator signal was closed and opening of parking brake reminder signal was
detected.
Action of
machine monitor Turns parking brake indicator and parking brake remind caution lamp ON.
Problem that
appears on
machine
Related
information
While parking brake is in intermediate position, parking brake reminder caution lamp does not light.
While parking brake is in intermediate position, parking brake reminder buzzer does not sound.
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
monitoring function.
(Monitoring code: MONITOR PANEL 40903 D-IN-26, 28)
(Monitoring code: MONITOR PANEL 40904 D-IN-35, 36)
Causes
Possible causes
and standard
value in normal
state
Defective diode
(Internal defect)


Disconnection in wiring harwithout turning starting switch ON.
2
or defective contact in conWiring harness between L27 (female) (2),
Resisnector)
Max. 1 z
(14) L53 (female) (2)
tance
ResisMin.
tance
1 Mz
40-350
16
If causes 1 3 are not detected, machine monitor may be defective.


(intermediate switch): Trouble
SEN03943-01
40-350
17

Failure code [DDB6L0] Parking brake reminder signal: Ground fault
SEN03943-01

Action code
Failure code
E01
DDB6L0
Contents of
trouble
Trouble
Parking brake reminder signal: Ground fault

While parking brake reminder signal operation signal of machine monitor was not input (open), parking brake reminder signal operation signal of HST controller was input (closed).
Action of
controller
When engine is stopped while parking brake is not applied securely, move-down prevention is not
controlled.
Problem that
appears on
machine
down suddenly.
Related
information

Causes
Defective diode
1
(Internal defect)


Disconnection in wiring harwithout turning starting switch ON.
2
or defective contact in conWiring harness between L27 (female) (2),
Resisnector)
Max. 1 z
(14) L53 (female) (2)
tance
Possible causes
and standard
value in normal
state

ResisMin.
tance
1 Mz
40-350
18

HST
Voltage
Between (6) ground
20 30 V

L27
Voltage
Max. 1 V

SEN03943-01
40-350
19

Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short
SEN03943-01
Failure code [DDB6L4] Parking brake indicator signal: Disconnection/

Hot short
Action code
Failure code
E03
DDB6L4
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Parking brake indicator signal: Disconnection/Hot short

HST controller detected disagreement with parking brake indicator signal from machine monitor.
(While signal was input to machine monitor (closed), signal was not input to HST controller (open).

Stops neutralizer (parking brake drag prevention function).
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
returned to neutral.
Since machine can travel forward and reverse while parking brake is applied, parking brake may be
damaged (Caution buzzer sounds in this case, however).
Causes
Defective diode
(Internal defect)

2
ResisMax. 1 z
nector)
L47 (female) (2)
tance
Possible causes
and standard
value in normal
state

ResisMin.
tance
1 Mz
4
24V circuit) in wiring harness Between wiring harness HST (female) (16)
Voltage Max. 1 V
40-350
20

HST
Voltage
Between (16) ground
Max. 1 V

L27
Voltage
20 30 V

Failure code [DDB6L4] Parking brake indicator signal: Disconnection/Hot short
SEN03943-01
40-350
21

Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault
SEN03943-01
Failure code [DDD7KX] Travel speed control dial signal: Disconnection/

Ground fault
Action code
Failure code
E01
DDD7KX
Contents of
trouble
Action of
controller
Trouble
Travel speed control dial signal: Disconnection/Ground fault

Travel speed control dial signal voltage lowered below 0.3 V.

Continue controls on assumption that travel speed control dial is set to minimum speed side.
Problem that
appears on
machine
Travel speed cannot be adjusted with travel speed control dial.

If speed range selector switch is set in 1st, travel speed is set to about 4 km/h.
Related
information
If failure code [DAJ5KX] is also displayed, carry out troubleshooting for it first.
Causes

Defective travel speed con1

trol dial (Internal defect)
Between L54 (female) (1) (3)
Voltage
4.7 5.3
V
Between L54 (female) (2) (3) (Max. speed

side of dial)
Voltage
0.3 0.9
V
Between L54 (female) (2) (3) (Min. speed

side of dial)
Voltage
4.1 4.7
V

Possible causes
and standard
value in normal
state
2
nector)
L54 (female) (1)
Resistance
Max. 1 z
Resistance
Max. 1 z

wiring harness HST (female) (23)
ResisMin.
cuit)
tance
1 Mz
40-350
22
HST (female)
Resistance
Between (32) ground
Max. 1 z

HST (female)
Voltage
Between (22) ground
4.7 5.3 V
Between (23) ground
0.3 4.7 V

Failure code [DDD7KX] Travel speed control dial signal: Disconnection/Ground fault
SEN03943-01
40-350
23

Failure code [DDD7KY] Travel speed control dial signal: Hot short
SEN03943-01
Action code
Failure code
E01
DDD7KY
Contents of
trouble
Action of
controller
Trouble
Travel speed control dial signal: Hot short

Travel speed control dial signal voltage exceeded 4.7 V.

None in particular.
Problem that
appears on
machine
Travel speed cannot be adjusted with travel speed control dial.

If speed range selector switch is set in 1st, travel speed is set to about 4 km/h.
Related
information
If failure code [DAJ5KX] is also displayed, carry out troubleshooting for it first.
Causes

Possible causes
and standard
value in normal
state
Defective travel speed control dial (Internal defect)
Voltage
4.7 5.3
V
Between L54 (female) (2) (3) (Max. speed

side of dial)
Voltage
0.3 0.9
V
Between L54 (female) (2) (3) (Min. speed

side of dial)
Voltage
4.1 4.7
V
2
ResisMax. 1 z
nector)
L54 (female) (3)
tance
Hot short (Contact with5 V,
3
Voltage Max. 1 V
40-350
24
HST (female)
Resistance
Between (32) ground
Max. 1 z

HST (female)
Voltage
Between (22) ground
4.7 5.3 V
Between (23) ground
0.3 4.7 V

SEN03943-01
40-350
25

Failure code [DDE5MA] Emergency steering operation switch: Disconnection
SEN03943-01
Failure code [DDE5MA] Emergency steering operation switch:

Disconnection
Action code
Failure code
E01
DDE5MA
Contents of
trouble
Trouble
Emergency steering operation switch: Disconnection

While engine was stopped, steering pump oil pressure was sensed because of disconnection in
steering oil pressure reduction switch (emergency steering operation switch) system.
Action of
None in particular.
machine monitor
Problem that
appears on
machine
Related
information
When steering oil pressure reduces, steering oil pressure caution lamp does not light.
This code is applied to only emergency steering specification model and is not turned ON if not
selected as option with machine monitor.
Input state (ON/OFF) from steering oil pressure reduction switch can be checked with monitoring
function.
Causes

and start engine and carry out troubleshooting in each case.
F11 (male)
Defective steering oil pres1 sure reduction switch (Internal defect)
Between (1) (2)
Between (1), (2)

ground
Possible causes
and standard
value in normal
state
Steering oil pressure
Resistance

(Engine is stopped)
Max. 1 z
Oil pressure normal

(Engine is running)
Min. 1 Mz
Normally
Min. 1 Mz

2
or defective contact in con- F11 (female) (1)
nector)
Between F11 (female) (2) ground
Resistance
Max. 1 z
Resistance
Max. 1 z

and start engine and carry out troubleshooting in each case.
L27
Between (16)
ground
40-350
26
Voltage

(Engine is stopped)
Max. 1 V
Oil pressure normal

(Engine is running)
20 30 V

Failure code [DDE5MA] Emergency steering operation switch: Disconnection
SEN03943-01
40-350
27

Failure code [DDK3KA] Directional selector switch: Disconnection/Hot short
SEN03943-01

Action code
Failure code
E03
DDK3KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Directional selector switch: Disconnection/Hot short

Since the directional selector switch input signal system is disconnected or not shorted, the directional selector switch signal is not recognized.
Sets to neutral.
Even if cause of failure disappears, system does not reset itself until the directional selector switch is
set to N (Neutral).
Machine travel with the right directional selector switch becomes unavailable.
Travel with FNR (directional) lever is available.
Shift lever position pilot lamp goes off.
Only for directional selector switch (if equipped)
Method of reproducing failure code: Turn the starting switch ON, turn the directional selector switch
ON/OFF switch ON, then operate the FNR (directional) switch.
Causes

MF1 (male)
Defective directional selector switch

1
short circuit)
Between (1) (2)

Between (1) (3)
Between (1) (4)
Between (1), (2), (3),
(4) and ground
Directional selector
switch
Resistance
F (Forward)
Max. 1 z
Other than above
Min. 1 Mz
N (Neutral)
Max. 1 z
Other than above
Min. 1 Mz
R (Reverse)
Max. 1 z
Other than above
Min. 1 Mz
Constant
Min. 1 Mz

Possible causes
and standard
value in normal
state

2

MF1 (female) (2)
Resistance
Max. 1 z

MF1 (female) (3)
Resistance
Max. 1 z

MF1 (female) (4)
Resistance
Max. 1 z
Wiring harness between MF1 (female) (1)

ground
Resistance
Max. 1 z

(Test with turning on the directional selector ON/OFF switch)
HST
Between (4) and

ground
Between (14) and
ground
Between (24) and
ground
40-350
28
Right FNR (directional) switch
Voltage
F (Forward)
Max. 1 V
Other than above
20 30 V
N (Neutral)
Max. 1 V
Other than above
20 30 V
R (Reverse)
Max. 1 V
Other than above
20 30 V

SEN03943-01
40-350
29

Failure code [DDK3KB] Directional selector switch: Ground fault
SEN03943-01

Action code
Failure code
E03
DDK3KB
Trouble
Directional selector switch: Ground fault

Contents of
trouble
Since the directional selector switch input signal system has a ground fault, the directional selector
switch signal is not recognized.
Action of
controller
Sets to neutral.
Even if cause of failure disappears, system does not reset itself until the directional selector switch is
set to N (Neutral).
Problem that
appears on
machine
Related
information
Machine travel with the directional selector switch becomes unavailable.

Travel with FNR (directional) lever is available.
Shift lever position pilot lamp goes off.
Only for right FNR (directional) switch (if equipped)
Method of reproducing failure code: Turn the starting switch ON, turn the directional selector switch
ON/OFF switch ON, then operate the directional selector switch.
Causes

MF1 (male)
Defective directional selector switch

1
short circuit)
Between (1) (2)

Between (1) (3)
Between (1) (4)
Between (1), (2), (3),
(4) and ground
Resistance
F (Forward)
Max. 1 z
Other than above
Min. 1 Mz
N (Neutral)
Max. 1 z
Other than above
Min. 1 Mz
R (Reverse)
Max. 1 z
Other than above
Min. 1 Mz
Constant
Min. 1 Mz

Possible causes
and standard
value in normal
state

MF1 (female) (2), L68 (female) (2) and
Grounding fault in wiring har- ground
2 ness
(Contact with ground circuit) Wiring harness between HST (female) (14)
MF1 (female) (3), D01 (female) (2) and
ground
MF1 (female) (4) and ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

(Test with turning on the directional selector ON/OFF switch)
HST
Between (4) and

ground
Between (14) and
ground
Between (24) and
ground
40-350
30
Voltage
F (Forward)
Max. 1 V
Other than above
20 30 V
N (Neutral)
Max. 1 V
Other than above
20 30 V
R (Reverse)
Max. 1 V
Other than above
20 30 V

SEN03943-01
40-350
31

Failure code [DDK6KA] FNR lever: Disconnection/Ground fault
SEN03943-01

Action code
Failure code
E03
DDK6KA
Trouble
FNR lever: Disconnection/Ground fault

Contents of
trouble
No signal of FNR (directional) lever is input because of disconnection or ground fault in FNR (directional) lever switch signal system.
Action of
controller
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).
If directional selector switch actuation switch is turned ON, FNR (directional) lever switch controls on
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 (Neutral).
Problem that
appears on
machine
Machine cannot be driven with FNR (directional) lever.

Machine can be driven with directional selector switch (only machine with directional selector switch
actuation switch).
Gear shift lever position lamp goes off.
Related
information
The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
function (Code: HST 40977 D-IN-0, D-IN-1 or D-IN-2).
Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever
Causes
1

box (FS1)

(See cause 5.)
Defective FNR (directional)

2 lever switch (Internal disconnection or short circuit)
Possible causes
and standard
value in normal
state
L15
FNR (directional)
lever
Voltage
Between (1) and

ground
Constant
20 30 V
N (Neutral)
20 30 V
Between (3) and

ground
Between (2) and
ground
Between (4) and
ground
Other than above
Max. 1 V
F (Forward)
20 30 V
Other than above
Max. 1 V
R (Reverse)
20 30 V
Other than above
Max. 1 V

Replace VIS power
Defective VIS power supply (L102) with another
3
holding relay (Internal defect) relay
Condition becomes
normal
Relay (L102) is
defective
Condition does not

become normal
Relay (L102) is
normal

40-350
32
Resistance
200
400 z

Causes
SEN03943-01


4

box (FS1) L102 (female) (5) and ground
Resistance
Max. 1 z

L15 (female) (1)
Resistance
Max. 1 z

L15 (female) (4)
Resistance
Max. 1 z

L15 (female) (3)
Resistance
Max. 1 z

L15 (female) (2)
Resistance
Max. 1 z

Possible causes
and standard
value in normal
state
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

L15 (female) (3), D01 (female) (5) and
ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Grounding fault in wiring har- ground
5 ness
(Contact with ground circuit) L15 (female) (4), L126 (female) (13) and
ground

HST
Between (5) and

ground
Between (34) and
ground
Between (15) and
ground
FNR (directional)
lever
Voltage
N (Neutral)
20 30 V
Other than above
Max. 1 V
F (Forward)
20 30 V
Other than above
Max. 1 V
R (Reverse)
20 30 V
Other than above
Max. 1 V
40-350
33
SEN03943-01

40-350
34

SEN03943-01
40-350
35

Failure code [DDK6KY] FNR lever: Hot short
SEN03943-01

Action code
Failure code
E03
DDK6KY
Contents of
trouble
Trouble
FNR lever: Hot short

Multiple FNR (directional) lever signals are input because of hot short in FNR (directional) lever
switch signal system.
Action of
controller
Sets gear in neutral.

If directional selector switch actuation switch is turned ON, machine is driven according to directional
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 (Neutral).
Problem that
appears on
machine
Operator cannot travel machine at position other than position having hot short with FNR (directional)
lever switch. (Example: When directional lever F system has hot short, if lever is set in F, trouble is
reset and machine can travel forward.)
Multiple gear shift lever position lamp lights.
Machine can be driven with directional selector switch (only machine with directional selector switch).
Related
information
The input state (ON/OFF) from the FNR (directional) lever switch can be checked with the monitoring
function (Code: HST 40977 D-IN-0, D-IN-1 or D-IN-2).
Method of reproducing failure code: Turn the starting switch ON and operate FNR (directional) lever
Causes


1 lever switch (Internal short
circuit)
Possible causes
and standard
value in normal
state
L15
FNR (directional)
lever
Voltage
Between (1) and

ground
Constant
20 30 V
Between (3) and

ground
F (Forward)
20 30 V
Other than above
Max. 1 V
Between (2) and

ground
N (Neutral)
20 30 V
Other than above
Max. 1 V
Between (4) and

ground
R (Reverse)
20 30 V
Other than above
Max. 1 V

2 (Contact with 5 V, 24V circuit)

Voltage
Max. 1 V

Voltage
Max. 1 V

Voltage
Max. 1 V

HST
36
Voltage
Between (5) and

ground
N (Neutral)
20 30 V
Other than above
Max. 1 V
Between (34) and

ground
F (Forward)
20 30 V
Other than above
Max. 1 V
R (Reverse)
20 30 V
Other than above
Max. 1 V
Between (15) and

ground
40-350
FNR (directional)
lever

SEN03943-01
40-350
37

Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)
SEN03943-01
Failure code [DDS5L6] Steering: Low oil pressure (Operation of

emergency steering)
Action code
Failure code
E03
DDS5L6
Contents of
trouble
Trouble
Steering: Low oil pressure (Operation of emergency steering)

While engine was running, steering oil pressure sensor signal was closed.
Action of
machine monitor Turns steering oil pressure warning lamp ON.
Problem that
appears on
machine
Related
information
Steering system does not work except when HST circuit oil pressure is high during travel etc.
This code is applied to only machine with emergency steering (optional).
Causes
1 Low steering oil pressure

System is normal.
a Carry out troubleshooting for hydraulic and mechanical systems.
F11 (male)
Defective steering oil pres2 sure sensor (switch) (Internal

defect)
Between (1) (2)
Possible causes
and standard
value in normal
state
Resistance
When oil pressure is

low
(While engine is
stopped)
Max. 1 z

normal
(While engine is
running)
Min. 1 Mz

3 ness (Contact with GND cirBetween wiring harness L27 (female) (16)
ResisMin.
cuit)
F11 (female) (1) and ground
tance
1 Mz
troubleshooting.
L27
Between (16)
ground
40-350
38
Voltage

abnormal (low) (below
0.5 MPa {5.1 kg/cm2})
Max. 1 V

normal (above 0.9
MPa {9.2 kg/cm2})
20 30 V

Failure code [DDS5L6] Steering: Low oil pressure (Operation of emergency steering)
SEN03943-01
40-350
39
SEN03943-01

2009 KOMATSU
All Rights Reserved
40-350
40
SEN03944-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
40 Troubleshooting
40

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
40-360
SEN03944-01

Failure code [DF10KA] Travel speed range selector switch: Disconnection/Ground fault
Failure code [DF10KA] Travel speed range selector switch:

Action code
Failure code
E01
DF10KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Travel speed range selector switch: Disconnection/Ground fault

Travel speed range selector switch signal is not input because of disconnection or ground fault in
travel speed range selector switch input signal system.
Fixes gear to speed range before error occurrence.
If trouble disappears, system resets itself.
Once starting switch is turned OFF, gear speed is assumed to be 4th for control, regardless of
selected speed range.
Gear is not set in selected speed range.
Indicator displays range before error occurrence.
(Once starting switch is turned OFF, 4th gear is displayed)
Method of reproducing failure code: Turn starting switch ON + Operate speed range selector switch.
Causes

L03 (female)
Between (1) (2)
Switch position
Resistance
2nd
Max. 1 z
Other than above
Min. 1 Mz
Between (1) (3)

Defective travel speed range
1 selector switch (Internal
defect)
Min. 1 Mz
Min. 1 Mz
3rd
Max. 1 z
4th
Max. 1 z
4th
Max. 1 z
Other than above
Min. 1 Mz
Between (2) (3)
(Anytime)
Min. 1 Mz
Between (2) (4)
(Anytime)
Min. 1 Mz
Between (1) (4)
Possible causes
and standard
value in normal
state
1st
2nd
Between (3) (4)
1st
Max. 1 z
2nd
Min. 1 Mz
3rd
Min. 1 Mz
4th
Max. 1 z

2 selector resistor (Internal
defect)
40-360
L70 (male)
Resistance
Between (1) (5)
100 z 1%
Between (2) (6)
220 z 1%
Between (3) (7)
330 z 1%
Between (4) (8)
470 z 1%

Causes
SEN03944-01

L70 (female) (7)
Resistance
Max. 1 z

L03 (female) (3), L70 (female) (5), (3)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

L70 (female) (8)
Resistance
Max. 1 z

L70 (female) (2) (4)
Resistance
Max. 1 z
3
nector)
L70 (female) (1)
Possible causes
and standard
value in normal
state

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

L03 (female) (3), L70 (female) (5), (3) and
Ground fault in wiring har4 ness (Contact with GND cir- ground
cuit)

HST
Between (39) (32)
Switch position
Voltage
1st
1.9 2.3 V
2nd
2.4 2.7 V
3rd
2.9 3.2 V
4th
3.3 3.7 V
40-360
SEN03944-01

40-360

SEN03944-01
40-360

Failure code [DF10KB] Travel speed range selector switch: Hot short
SEN03944-01
Action code
Failure code
E01
DF10KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Travel speed range selector switch: Hot short

Multiple travel speed range selector switch signal is input because of hot short in travel speed range
selector switch input signal system.
Fixes gear to speed range before error occurrence.
If trouble disappears, system resets itself.
Once starting switch is turned OFF, gear speed is assumed to be 4th for control, regardless of
selected speed range.
Gear is not set in selected speed range.
Indicator displays range before error occurrence.
(Once starting switch is turned OFF, 4th gear is displayed)
Method of reproducing failure code: Turn starting switch ON + Operate speed range selector switch.
Causes

L03 (female)
Between (1) (2)
Switch position
2nd
Max. 1 z
Other than above
Min. 1 Mz
1st
Min. 1 Mz
2nd
Min. 1 Mz
Between (1) (3)
3rd
Max. 1 z
4th
Max. 1 z
4th
Max. 1 z
Other than above
Min. 1 Mz

1 selector switch (Internal
defect)
Between (1) (4)
Possible causes
and standard
value in normal
state
Resistance
Between (2) (3)
(Anytime)
Min. 1 Mz
Between (2) (4)
(Anytime)
Min. 1 Mz
1st
Max. 1 z
2nd
Min. 1 Mz
3rd
Min. 1 Mz
4th
Max. 1 z
Between (3) (4)

2 selector resistor (Internal
defect)
L70 (male)
Resistance
Between (1) (5)
100 z 1%
Between (2) (6)
220 z 1%
Between (3) (7)
330 z 1%
Between (4) (8)
470 z 1%


3
ground
40-360
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V

Causes
Hot short (Contact with 24V

3 circuit) in wiring harness
Possible causes
and standard
value in normal
state

Voltage
Max. 1 V

Voltage
Max. 1 V

L70 (female) (2) (4) and ground
Voltage
Max. 1 V
HST
SEN03944-01
Between (39) (32)
Switch position
Voltage
1st
1.9 2.3 V
2nd
2.4 2.7 V
3rd
2.9 3.2 V
4th
3.3 3.7 V
40-360

Failure code [DGH1KX] HST oil temperature sensor: Ground fault
SEN03944-01
Failure code [DGH1KX] HST oil temperature sensor: Ground fault

Action code
Failure code
E01
DGH1KX
Contents of
trouble
Trouble
HST oil temperature sensor: Ground fault

HST oil temperature higher than 150C was detected. (Ground fault in HST oil temperature signal
circuit was detected.)
Action of
HST oil overheat is not detected.
machine monitor
Problem that
appears on
machine
Related
information
HST oil temperature gauge indicates maximum.

Input state from HST oil temperature sensor can be checked with monitoring function.
(Monitoring code: MONITOR PANEL 04408 HST OIL TEMP (C)
(Monitoring code: MONITOR PANEL 04409 HST OIL TEMP (V)
Causes

T10 (male)
Defective HST oil tempera1

ture sensor (Internal defect)
Possible causes
and standard
value in normal
state
Between (1) (2)

Between (1) (2) and
ground
HST oil temperature
Resistance
At 25C
35 50 kz
At 100C
3.1 4.5 kz
(Anytime)
Min. 1 Mz

wiring harness L28 (female) (2)
Resiscuit)
Min. 1 Mz
T10 (female) (1) and ground
tance
L28 (female)
Between (2) ground
HST oil temperature
Voltage
At 25C
4.4 4.6 V
At 100C
2.1 2.3 V
40-360

Failure code [DGR2KB] Brake oil temperature sensor: Ground fault
SEN03944-01
Failure code [DGR2KB] Brake oil temperature sensor: Ground fault

Action code
Failure code
E01
DGR2KB
Contents of
trouble
Trouble
Brake oil temperature sensor: Ground fault

Front brake oil temperature above 150C was detected.

(Ground fault was detected in front brake oil temperature signal circuit.)
Action of
Brake oil overheat is not detected.
machine monitor
Problem that
appears on
machine
Related
information
Brake oil temperature gauge indicates upper limit.

Brake performance lowers (while system is normal).
Input state from front brake oil temperature sensor 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 resets itself after brake oil temperature reduces below 130C.
Causes
Front brake overheat
1
(When system is normal)

Check for cause of overheat directly.
Possible causes
and standard
value in normal
state
Defective front brake (axle)

2 oil temperature sensor (Internal defect)
F14 (male)
Between (1) (2)
Between (1) (2) and
ground
Brake oil temperature
Resistance
At 25C
35 50 kz
At 100C
3.1 4.5 kz
(Anytime)
Min. 1 Mz
Ground fault in wiring harBetween wiring harness F14 (female) (1)

3 ness (Contact with GND cirL28 (female) (7) and ground
cuit)
Resistance
Min. 1 Mz

L25, L28
Voltage
Between L28 (7)

L25 (9)
At 25C
4.4 4.6 V
At 100C
2.1 2.3 V
40-360

Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short
SEN03944-01
Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/

Hot short
Action code
Failure code
E01
DGR2KZ
Contents of
trouble
Trouble
Brake oil temperature sensor: Disconnection/Hot short

Disconnection or hot short was detected in front brake oil temperature signal circuit.
Reference: Detection is made by sudden change of brake oil temperature or by logic of comparison
with HST oil temperature.
Action of
None in particular.
machine monitor
Problem that
appears on
machine
Related
information
Brake oil temperature gauge indicates lower limit.

Brake may be broken and brake may not work because of brake oil temperature error.
Input state from front brake oil temperature sensor 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 resets itself after brake oil temperature increases above 25C.
Causes
Defective front brake (axle)

1 oil temperature sensor (Internal defect)

F14 (male)
Between (1) (2)
Resistance
At 25C
35 50 kz
At 100C
3.1 4.5 kz

Possible causes
and standard
value in normal
state
Disconnection in wiring harness (Disconnection in wiring Wiring harness between F14 (female) (1)
2
nector)
Wiring harness between F14 (female) (2)
L25 (female) (9)
Resistance
Max. 1 z
Resistance
Max. 1 z

3
Hot short (Contact with 5 V, Between wiring harness F14 (female) (1)
24V circuit) in wiring harness L28 (female) (7) and ground
Voltage
Max. 1 V
Between wiring harness F14 (female) (2)

Voltage
Max. 1 V

40-360
10
L25, L28
Voltage
Between L28 (7)

L25 (9)
At 25C
4.4 4.6 V
At 100C
2.1 2.3 V

Failure code [DGR2KZ] Brake oil temperature sensor: Disconnection/Hot short
SEN03944-01
40-360
11

Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault
SEN03944-01
Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground

fault
Action code
Failure code
E03
DHH1KX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
HST oil pressure sensor: Disconnection/Ground fault

HST oil pressure sensor signal is not input because of disconnection or ground fault in HST oil pressure sensor system (Input voltage is below 0.3 V)
If trouble occurs during travel, control value (output) before trouble occurrence is held.
Once machine stops, gear is assumed to be in 1st for control.
Once machine stops, gear is set in 1st. (Travel speed can be controlled with travel speed control
dial, however.)
If [DAJ5KX] is displayed, carry out troubleshooting for it first.
Input state from HST oil pressure sensor can be checked with monitoring function.
(Monitoring code: HST 32600 HST PRESS (MPa))
(Monitoring code: HST 32601 HST PRESS (V))
Causes

a Prepare with starting switch OFF, then turn starting twitch ON and
Defective HST oil pressure

T11
Voltage
Between (C) (A)
0.5 4.5 V
Between (B) (A)
46V

Possible causes
and standard
value in normal
state

2

T11 (female) (C)
Resistance
Max. 1 z

T11 (female) (A)
Resistance
Max. 1 z

T11 (female) (B)
Resistance
Max. 1 z

Ground fault in wiring harBetween wiring harness HST (female) (33)
3 ness (Contact with GND cirT11 (female) (C) and ground
cuit)
T11 (female) (B) and ground
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz
troubleshooting.
40-360
12
HST
Voltage
Between (33) (32)
0.5 4.5 V
Between (22) (32)
46V

Failure code [DHH1KX] HST oil pressure sensor: Disconnection/Ground fault
SEN03944-01
40-360
13

Failure code [DHH1KY] HST oil pressure sensor: Hot short
SEN03944-01

Action code
Failure code
E03
DHH1KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
HST oil pressure sensor: Hot short

Abnormal HST oil pressure sensor signal was input because of hot short in HST oil pressure sensor
system (Input voltage was above 4.7 V).
If trouble occurs during travel, control value (output) before trouble occurrence is held.
Once machine stops, gear is assumed to be in 1st for control.
Once machine stops, gear is set in 1st. (Travel speed can be controlled with travel speed control
dial, however.)
If [DAJ5KX] is displayed, carry out troubleshooting for it first.
Input state from HST oil pressure sensor can be checked with monitoring function.
(Monitoring code: HST 32600 HST PRESS (MPa))
(Monitoring code: HST 32601 HST PRESS (V))
Causes

troubleshooting.
Possible causes
and standard
value in normal
state
Defective HST oil pressure

T11
Voltage
Between (C) (A)
0.5 4.5 V
Between (B) (A)
46V

2
Voltage Max. 1 V
T11 (female) (C) and ground
troubleshooting.
40-360
14
HST
Voltage
Between (33) (32)
0.5 4.5 V
Between (22) (32)
46V

SEN03944-01
40-360
15

Failure code [DHTCL6] HST filter clogging sensor: Functional defect
SEN03944-01

Action code
Failure code
E01
DHTCL6
Contents of
trouble
Trouble
HST filter clogging sensor: Functional defect

When engine stopped, HST filter clogging sensor was turned ON (Ground fault was detected).
Action of
Turns HST filter clogging caution lamp OFF.
machine monitor
Problem that
appears on
machine
Related
information
Foreign matter may enter HST hydraulic circuit.

Input state (ON/OFF) of HST filter clogging sensor can be checked with monitoring function.
Causes
Defective HST filter clogging
1
Possible causes
and standard
value in normal
state

Wiring harness between T13 T14
Resistance
Min. 1 Mz

wiring harness L26 (female) (5)
Resiscuit)
Min. 1 Mz
T13 and ground
tance
If causes 1 2 are not detected, machine monitor may be defective.

40-360
16

SEN03944-01
40-360
17

Failure code [DJF1KA] Fuel level sensor: Disconnection/Hot short
SEN03944-01

Action code
Failure code
E01
DJF1KA
Contents of
trouble
Trouble
Fuel level sensor: Disconnection/Hot short

Voltage above 4 V was detected in fuel level sensor signal circuit.
Action of
None in particular.
machine monitor
Problem that
appears on
machine
Fuel level gauge does not indicated normally (but keeps indicating empty).
Related
information
Input signal from fuel level sensor can be checked with monitoring function.
(Monitoring code: MONITOR PANEL 04200 FUEL SENSOR (V))
(Monitoring code: MONITOR PANEL 04202 FUEL SENSOR (%))
Causes

Defective fuel level sensor

(Internal defect)
R21 (male)
Fuel level
Resistance
When full
7 11 z
Between (1) (2)
When 1/2
25 35 z
When empty
60 95 z

Possible causes
and standard
value in normal
state
2
or defective contact in con- R21 (female) (1)
nector)
R21 (female) (2)
Resistance
Max. 1 z
Resistance
Max. 1 z

3

(Value is upper limit when empty.)
Voltage
Max. 2 V

R21 (female) (2)
Voltage
Max. 1 V

L26, L28
Between L28 (1)
L26 (6)
40-360
18
Fuel level
Voltage
When full
0.1 0.4 V
When 1/2
0.7 1.0 V
When empty
1.4 2.0 V

SEN03944-01
40-360
19

Failure code [DLT3KX] Travel speed sensor B: Abnormality
SEN03944-01

Action code
Failure code
E03
DLT3KX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Travel speed sensor B: Abnormality

While machine was traveling at speed above about 4 km/h, input signal of travel speed sensor B was
lost.
Recognizes travel speed by input signal of travel speed sensor A.
None in particular.
If failure code [DLT3KX] and [DLT4KX] (Travel speed sensor A: Abnormality) are turned ON simultaneously, see causes 6 and after.
Causes

a Prepare with starting switch OFF, then start engine (but do not
travel) and carry out troubleshooting.
Defective travel speed sensor (Internal defect)
T09
Voltage
Between (1) (2)
4.7 5.3 V
Between (2) ground
Max. 1 V
a Prepare with starting switch OFF, then start engine, travel at constant speed, and carry out troubleshooting.
T09
Voltage
Between (4) (2)
Below 1 V Above 4 V
(Changes at regular intervals)
2
ResisMax. 1 z
nector)
T09 (female) (4)
tance
Possible causes
and standard
value in normal
state

Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then start engine, travel at conGround fault in wiring harstant speed, and carry out troubleshooting.
Below 1 V
Above
Between wiring harness HST (36) T09 (4)
4V
Voltage
and ground
(Changes
at regular
intervals)
4
40-360
20

24V circuit) in wiring harness Between wiring harness HST (36) T09 (4)
and ground
Voltage
Below 1 V
Above
4V
(Changes
at regular
intervals)

Causes
SEN03944-01

troubleshooting without traveling.
Possible causes
and standard
value in normal
state
HST
Voltage
Between (22) (32)
4.7 5.3 V
Between (32) ground
Max. 1 V
HST
Voltage
Between (36) (32)
Below 1 V Above 4 V
40-360
21

SEN03944-01
a
When [DLT3KX] and [DLT4KX] (Travel speed sensor A: Abnormality) are turned ON simultaneously
Contents of
trouble
While machine was traveling at speed above about 4 km/h, input signals of travel speed sensors A
and B were lost.
Action of
controller
Keeps outputs to HST motor 1, HST motor 2 and clutch at values before trouble.
Keeps output values after clutch is engaged or disengaged completely, if clutch is being controlled.
Problem that
appears on
machine
Related
information
Travel speed does not increase or traction force is insufficient.

Machine monitor indicates 0 km/h as travel speed.
If trouble occurs while machine is stopped or traveling at low speed (below about 4 km/h), error is not
turned ON.
In above case, machine monitor indicates 0 km/h as travel speed and actual travel speed is limited to
4 7 km/h.
Causes

Defective travel speed sen6

sor (Internal defect)
T09
Voltage
Between (1) (2)
4.7 5.3 V
Between (2) ground
Max. 1 V
T09
Voltage
Between (3) (2)
Below 1 V Above 4 V
Between (4) (2)
Below 1 V Above 4 V

Possible causes
and standard
value in normal
state

T09 (female) (1)
7
or defective contact in con- T09 (female) (2)
nector)
T09 (female) (3)
T09 (female) (4)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

Ground fault in wiring harT09 (female) (1) and ground
cuit)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

9
Voltage Max. 1 V
and ground
40-360
22

Causes
SEN03944-01

Possible causes
and standard
value in normal 10 Defective HST controller
state
HST
Voltage
Between (22) (32)
4.7 5.3 V
Between (32) ground
Max. 1 V
HST
Voltage
Between (26) (32)
Below 1 V Above 4 V
Between (36) (32)
Below 1 V Above 4 V
40-360
23

Failure code [DLT4KX] Travel speed sensor A: Abnormality
SEN03944-01

Action code
Failure code
E03
DLT4KX
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Travel speed sensor A: Abnormality

While machine was traveling at speed above about 4 km/h, input signal of travel speed sensor A was
lost.
Recognizes travel speed by input signal of travel speed sensor B.
None in particular.
If failure code [DLT4KX] and [DLT3KX] (Travel speed sensor B: Abnormality) are turned ON simultaneously, see [DLT3KX], causes 6 and after.
Causes

Defective travel speed sensor (Internal defect)
T09
Voltage
Between (1) (2)
4.7 5.3 V
Between (2) ground
Max. 1 V
T09
Voltage
Between (3) (2)
Below 1 V Above 4 V
2
ResisMax. 1 z
nector)
T09 (female) (3)
tance
Possible causes
and standard
value in normal
state

Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then start engine, travel at conGround fault in wiring harstant speed, and carry out troubleshooting.
Below 1 V
Above
4V
Voltage
and ground
(Changes
at regular
intervals)
4
40-360
24

and ground
Voltage
Below 1 V
Above
4V
(Changes
at regular
intervals)

Causes
SEN03944-01

Possible causes
and standard
value in normal
state
HST
Voltage
Between (22) (32)
4.7 5.3 V
Between (32) ground
Max. 1 V
HST
Voltage
Between (26) (32)
Below 1 V Above 4 V
40-360
25

Failure code [DLT4LC] Travel speed sensor A & B: Abnormality
SEN03944-01

Action code
Failure code
E03
DLT4LC
Contents of
trouble
Action of
controller
Trouble
Travel speed sensor A & B: Abnormality

Difference between values sensed by travel speed sensors A and B during travel is large.
None in particular other than above (Uses higher value normally).
Problem that
appears on
machine
Related
information
Even trouble disappears, system does not reset itself until engine is started again.
Causes

travel) and carry out troubleshooting without traveling.
Defective travel speed sen1

sor (Internal defect)
T09
Voltage
Between (1) (2)
4.7 5.3 V
Between (2) ground
Max. 1 V
T09
Voltage
Between (3) (2)
Below 1 V Above 4 V
Between (4) (2)
Below 1 V Above 4 V

Possible causes
and standard
value in normal
state
2
nector)
T09 (female) (4)
Resistance
Max. 1 z
Resistance
Max. 1 z

Ground fault in wiring harBetween wiring harness HST (female) (26)
3 ness (Contact with GND cirT09 (female) (3) and ground
cuit)
T09 (female) (4)
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

4
26
Voltage
Below 1 V
Above
4V
(Changes
at regular
intervals)


T09 (female) (4)
40-360
Voltage
Below 1 V
Above
4V
(Changes
at regular
intervals)

Causes
SEN03944-01

Possible causes
and standard
value in normal
state
HST
Voltage
Between (22) (32)
4.7 5.3 V
Between (32) ground
Max. 1 V
HST
Voltage
Between (26) (32)
Below 1 V Above 4 V
Between (36) (32)
Below 1 V Above 4 V
40-360
27

Failure code [DV00KY] Alarm buzzer: Hot short
SEN03944-01

Action code
Failure code
E01
DV00KY
Contents of
trouble
Trouble
Alarm buzzer: Hot short

The alarm buzzer output circuit is shorted with the power source.
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
appears on
machine
Related
information
Alarm buzzer does not sound.

Backup alarm/lamp may not operate.
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.
(Code: MONITOR PANEL 40952 D-OUT-2)
Output state (ON/OFF) to ECSS relay can be checked with monitoring function.
(Code: MONITOR PANEL 40952 D-OUT-3)
Causes
Possible causes
and standard
value in normal
state
Defective alarm buzzer

40-360
28

L46 (female) (2) and chassis ground
Voltage
Max. 1 V

Remove the buzzer, then connect +24 V to L46 (male) (1) and
GND to L46 (male) (2).
Alarm buzzer sounds
Alarm buzzer is
normal
Alarm buzzer does not sound
Defective alarm
buzzer
When above 1 and 2 are normal, failure on the machine monitor

can be suspected. (Since trouble is in system, troubleshooting
cannot be carried out.)

SEN03944-01
40-360
29

Failure code [DW26KA] Motor 2 solenoid: Disconnection/Ground fault
SEN03944-01

Action code
Failure code
E01
DW26KA
Trouble
Motor 2 solenoid: Disconnection/Ground fault

Contents of
trouble
Motor 2 cannot be controlled because of disconnection or ground fault in motor 2 solenoid relay output system.
Action of
controller
Keeps output to motor 2 solenoid relay turned OFF (If there is ground fault, output cannot be turned
OFF actually).
Problem that
appears on
machine
Related
information
When there is disconnection: Travel speed is not limited and maximum speed is equivalent to 4th
gear speed in 3rd speed range.
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.
(Monitoring code: HST 40980 D-OUT-16)
Method of reproducing failure code: Travel at speed above about 11 km/h in 4th speed range.
Causes


relay (Internal defect)
Replace motor 2
solenoid relay (L103)
with another relay.
Condition becomes
normal
Relay (L103) is
defective
Condition does not

become normal
Relay (L103) is
normal

Resistance
200
400 z
troubleshooting.

circuit)
Possible causes
and standard
value in normal
state
Replace VIS power

(L102) with another
relay.
Condition becomes
normal.
Relay (L102) is
defective.
Condition does not

become normal.
Relay (L102) is
normal.

Resistance
200
400 z

3
nector)
L102 (female) (3)
Resistance
Max. 1 z
Resistance
Max. 1 z

Resiscuit)
Min. 1 Mz
tance
a Prepare with starting switch OFF, then start engine, travel, and
HST
Condition
Voltage
Stopped
Max. 1 V
Between (27)
ground
Speed range: 4th

Travel speed: Above
11 km/h
20 30 V
40-360
30

SEN03944-01
40-360
31

Failure code [DW26KY] Motor 2 solenoid: Hot short
SEN03944-01

Action code
Failure code
E01
DW26KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Motor 2 solenoid: Hot short

Motor 2 solenoid cannot be operated because of hot short in motor 2 solenoid relay output system.
Keeps output to motor 2 solenoid relay turned OFF.
When the gear is shifted to 3rd, travel speed is not limited and maximum travel speed is equivalent to
4th-gear speed.
Output state (ON/OFF) to motor 2 solenoid relay can be checked with monitoring function.
Causes


Condition becomes
Replace motor 2
normal
Condition does not
with another relay.
become normal
Relay (L103) is
defective
Relay (L103) is
normal

Possible causes
and standard
value in normal
state
Resistance

circuit) in wiring harness
200
400 z

L103 (female) (2)
Voltage
(When
stopped)
Max. 1 V

40-360
32
HST
Voltage
Between (27) ground
Max. 1 V

SEN03944-01
40-360
33

Failure code [DW7BKY] Fan reverse solenoid circuit: Hot short
SEN03944-01

Action code
Failure code
E01
DW7BKY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan reverse solenoid circuit: Hot short

Abnormal voltage was generated because of hot short in fan reverse solenoid relay output system
when fan reverse solenoid relay output was turned ON.
Keeps output to fan reverse solenoid turned OFF and stops fan reverse control function.
Fan does not reverse (Manual reverse function and automatic reverse function do not work).
Output state (ON/OFF) to fan reverse solenoid relay can be checked with monitoring function.
Method of reproducing failure code: Start engine, wait for at least 30 seconds, and then press manual reverse switch.
Causes

Defective fan reverse solenoid relay (Internal defect)
Condition becomes
Replace fan reverse normal
Condition does not
with another relay.
become normal
Relay (L104) is
defective
Relay (L104) is
normal

Possible causes
and standard
value in normal
state
Resistance
200
400 z
troubleshooting.
2

Voltage (In fan for24V circuit) in wiring harness Wiring harness between HST
ward mode)
(female) (37) L104 (female) (2) Voltage (In fan
reverse mode)
20 30 V
Max. 1 V
troubleshooting.
40-360
34
HST
Fan condition
Voltage
Between (37)
ground
In fan forward mode
20 30 V
In fan reverse mode
Max. 1 V

SEN03944-01
40-360
35

Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault
SEN03944-01
Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/

Ground fault
Action code
Failure code
E01
DW7BKZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan reverse solenoid circuit: Disconnection/Ground fault

Fan reverse solenoid relay cannot be controlled because of disconnection or ground fault in fan
reverse solenoid relay output system.
Keeps output to fan reverse solenoid turned OFF and stops fan reverse control function.
Manual reverse function and automatic reverse function do not work.
Fan always turns forward (When there is disconnection).
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.
Causes

Defective fan reverse solenoid relay (Internal defect)
Condition becomes
Replace fan reverse normal
Condition does not
with another relay.
become normal
Relay (L104) is
defective
Relay (L104) is
normal

Resistance
200
400 z
troubleshooting.
Possible causes
and standard
value in normal
state

circuit)
Replace VIS power

(L102) with another
relay.
Condition becomes
normal.
Relay (L102) is
defective.
Condition does not

become normal.
Relay (L102) is
normal.

Resistance
200
400 z

3
nector)
L102 (female) (3)
Resistance
Max. 1 z
Resistance
Max. 1 z

Resiscuit)
Min. 1 Mz
tance
troubleshooting.
40-360
36
HST
Fan condition
Voltage
Between (37)
ground
In fan forward mode
20 30 V
In fan reverse mode
Max. 1 V

Failure code [DW7BKZ] Fan reverse solenoid circuit: Disconnection/Ground fault
SEN03944-01
40-360
37
SEN03944-01

2009 KOMATSU
All Rights Reserved
40-360
38
SEN03945-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
40 Troubleshooting
40

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
40-370

Failure code [DX16KA] Fan EPC solenoid: Disconnection
SEN03945-00
Failure code [DX16KA] Fan EPC solenoid: Disconnection

Action code
Failure code
E01
DX16KA
Trouble
Fan EPC solenoid: Disconnection

Contents of
trouble
Since the fan EPC solenoid system is disconnected, no current flows when the fan EPC solenoid
output is ON.
Action of
controller
Problem that
appears on
machine
Related
information
The fan speed is set to the maximum.

If [DX16KY] is displayed, carry out troubleshooting for it first.
The output state (current) to the fan EPC solenoid can be checked with the monitoring function
(Code: HST 41400 FAN EPC DIR).
Causes
1
Possible causes
and standard
value in normal
state
Defective fan EPC solenoid


2

R29 (male)
Resistance
Between (1) (2)
5 10 z

R29 (female) (2)
Resistance
Max. 1 z

R29 (female) (1)
Resistance
Max. 1 z
If causes 1 2 are not detected, HST controller may be defective.

40-370

Failure code [DX16KB] Fan EPC solenoid: Ground fault
SEN03945-00
Failure code [DX16KB] Fan EPC solenoid: Ground fault

Action code
Failure code
E01
DX16KB
Trouble
Fan EPC solenoid: Ground fault

Contents of
trouble
Since the fan EPC solenoid system is shorted, abnormal current flows when the fan EPC solenoid
output is ON.
Action of
controller
Turns the output to the fan EPC solenoid OFF.

Problem that
appears on
machine
Related
information
The fan speed is set to the maximum.

Causes

1
Possible causes
and standard
value in normal
state

R29 (male)
Resistance
Between (1) (2)
5 10 z
Between (1), (2) and ground
Min. 1 Mz

Grounding fault in wiring harwithout turning starting switch ON.
2 ness
Resis(Contact with ground circuit) Wiring harness between HST (female) (29)
Min. 1 Mz
tance

40-370

Failure code [DX16KY] Fan EPC solenoid: Hot short
SEN03945-00

Action code
Failure code
E01
DX16KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Fan EPC solenoid: Hot short

Since the fan EPC solenoid system is shorted with the power source, abnormal voltage is applied
when the fan EPC solenoid output is OFF.
Turns the output to the fan EPC solenoid OFF.
The fan speed is minimized.
Causes

1
Possible causes
and standard
value in normal
state


R29 (male)
Resistance
Between (1) (2)
5 10 z
Min. 1 Mz

Voltage
Max. 1 V

40-370

SEN03945-00
40-370

Failure code [DX19KA] Motor 1 solenoid: Disconnection
SEN03945-00

Action code
Failure code
E03
DX19KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Motor 1 solenoid: Disconnection

Disconnection was detected in motor 1 solenoid circuit.

(Difference between output command value and actual current is large.)

Traction force is decreased.

If failure code [DX19KY] or [DX20KY] is also displayed, carry out troubleshooting for it first.
Causes


(Internal defect)
T06 (male)
Resistance
Between (1) (2)
15 30 z
Min. 1 Mz

2
Possible causes
and standard
value in normal
state

T06 (female) (1)
Resistance
Max. 1 z

L111 (female) (3)
Resistance
Max. 1 z

HST (female) (40)
Resistance
Max. 1 z


(L111) (Internal defect)
Replace HST safety

relay (L111) with
another relay
Condition becomes
normal
Relay (L111) is
defective
Condition does not

become normal
Relay (L111) is
normal
a Prepare with starting switch OFF and check safety relay unit.
Apply 24 V between
Between L111 (male) (1) (2).
(3) (5)
Apply no voltage
between (1) (2).
40-370
Resistance
Max. 1 z
Resistance
Min. 1 Mz


SEN03945-00
40-370

Failure code [DX19KB] Motor 1 solenoid: Ground fault
SEN03945-00

Action code
Failure code
E03
DX19KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Motor 1 solenoid: Ground fault

Ground fault was detected in motor 1 solenoid circuit.


Causes

1
Possible causes
and standard
value in normal
state
T06 (male)
Resistance
Between (1) (2)
15 30 z
Min. 1 Mz

Resiscuit)
Min. 1 Mz
tance
3
40-370

(Internal defect)



SEN03945-00
40-370

Failure code [DX19KY] Motor 1 solenoid: Hot short
SEN03945-00

Action code
Failure code
E03
DX19KY
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Motor 1 solenoid: Hot short

Hot short was detected in motor 1 solenoid circuit.


[DX19KA], [DX20KA] or [DX20KY] may be also displayed, depending on condition when error was
detected.
Causes


(Internal defect)
T06 (male)
Resistance
Between (1) (2)
15 30 z
Min. 1 Mz

Possible causes
and standard
value in normal
state
Between wiring harness T06 (female) (1)

HST (female) (19)
2
40-370
10
Max. 1 V

Voltage Max. 1 V
L111 (female) (3) and ground.
(Check with traction control OFF and machine stopped.)
T06 (female) (1)
Voltage

Voltage
10 15 V


SEN03945-00
40-370
11

Failure code [DX20KA] Clutch EPC solenoid: Disconnection
SEN03945-00

Action code
Failure code
E03
DX20KA
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Clutch EPC solenoid: Disconnection

Disconnection was detected in clutch EPC solenoid circuit.

(When output command was above 250 mA, difference between command value and sensed current exceeded 200 mA.)


If failure code [DX19KY] or [DX20KY] is also displayed, carry out troubleshooting for it first.
Causes

Defective clutch EPC solenoid (Internal defect)
T05 (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz

2
Possible causes
and standard
value in normal
state

T05 (female) (1)
Resistance
Max. 1 z

L111 (female) (3)
Resistance
Max. 1 z

HST (female) (40)
Resistance
Max. 1 z


Replace HST safety

relay (L111) with
another relay
Condition becomes
normal
Relay (L111) is
defective
Condition does not

become normal
Relay (L111) is
normal
a Prepare with starting switch OFF and check safety relay unit.
Apply 24 V between
Between L111 (male) (1) (2).
(3) (5)
Apply no voltage
between (1) (2).
40-370
12
Resistance
Max. 1 z
Resistance
Min. 1 Mz


SEN03945-00
40-370
13

Failure code [DX20KB] Clutch EPC solenoid: Ground fault
SEN03945-00

Action code
Failure code
E03
DX20KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Clutch EPC solenoid: Ground fault

Ground fault was detected in clutch EPC solenoid circuit.


Causes

1
Possible causes
and standard
value in normal
state
14
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz

Resiscuit)
Min. 1 Mz
tance
40-370
T05 (male)


SEN03945-00
40-370
15

Failure code [DX20KY] Clutch EPC solenoid: Hot short
SEN03945-00

Action code
Failure code
E03
DX20KY
Contents of
trouble
Action of
controller
Trouble
Clutch EPC solenoid: Hot short

Hot short was detected in clutch EPC solenoid circuit.

Problem that
appears on
machine

Related
information

[DX19KA], [DX19KY] or [DX20KA] may be also displayed, depending on condition when error was
detected.
Causes

T05 (male)
Resistance
Between (1) (2)
5 15 z
Min. 1 Mz

Possible causes
and standard
value in normal
state

16
Max. 1 V

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))
40-370
Voltage
Voltage
10 15 V


SEN03945-00
40-370
17

Failure code [DXH7KB] Reverse solenoid: Ground fault
SEN03945-00

Action code
Failure code
E03
DXH7KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Reverse solenoid: Ground fault

Reverse solenoid is not turned ON.

Turns output to reverse solenoid OFF.
Machine does not travel in reverse.
Output state to HST pump R (Reverse) solenoid of HST controller can be checked with monitoring
function.
Causes

Defective reverse solenoid

(Internal defect)
Defective diode
(Internal defect)
T01 (male)
Resistance
Between (3) (4)
15 30 z
Min. 1 Mz

Between T01B (male) (1) (2)
No continuity
troubleshooting.
Possible causes
and standard
value in normal
state
Condition becomes
Replace FR pressure normal
select relay (L101)
Defective FR pressure select with another relay
Condition does not
3
become normal
Relay (L101) is
defective
Relay (L101) is
normal

Resistance
200
400 z

wiring harness HST (female) (20)
Resiscuit)
Min. 1 Mz
tance
40-370
18
a Prepare with starting switch OFF, then start engine, release parking brake, set directional lever in R position, and carry out troubleshooting.
HST
Voltage
Between (20) ground
20 30 V

SEN03945-00
40-370
19

Failure code [DXH7KZ] Reverse solenoid: Disconnection/Hot short
SEN03945-00

Action code
Failure code
E03
DXH7KZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Reverse solenoid: Disconnection/Hot short

Reverse solenoid is not turned ON (HST pressure selector relay does not operate) (when there is
disconnection).
Reverse solenoid cannot be turned OFF (Where there is hot short).
Turns output to reverse solenoid OFF.
Machine does not travel in reverse (when there is disconnection).
Machine may start in reverse suddenly (when there is hot short).
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
function.
Causes


(Internal defect)
Defective diode
2
(Internal defect)
T01 (male)
Resistance
Between (3) (4)
15 30 z
Min. 1 Mz

Between T01B (male) (2) (1)
No continuity

Condition becomes
Replace FR pressure normal
select relay (L101)
Condition does not
Defective FR pressure select with another relay
3
become normal
Relay (L101) is
defective
Relay (L101) is
normal

Possible causes
and standard
value in normal
state
Resistance
200
400 z

Resis4
Max. 1 z
tance
nector)
ResisMax. 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.
HST
Between (20)
ground
40-370
20
Directional lever
position
Voltage
R (Reverse)
20 30 V
Other than above
Max. 1 V

SEN03945-00
40-370
21

Failure code [DXH8KB] Forward solenoid: Ground fault
SEN03945-00

Action code
Failure code
E03
DXH8KB
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Forward solenoid: Ground fault

Forward solenoid is not turned ON.

Turns output to forward solenoid OFF.
Machine does not travel forward.
Output state to HST pump F (Forward) solenoid of HST controller can be checked with monitoring
function.
Causes

Possible causes
and standard
value in normal
state
Defective forward solenoid

(Internal defect)
Defective diode
(Internal defect)
22
Resistance
Between (1) (2)
15 30 z
Min. 1 Mz

Between T01A (male) (1) (2)
No continuity

Ground fault in wiring har3 ness (Contact with GND cirBetween wiring harness HST (female) (10)
cuit)
40-370
T01 (male)
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then start engine, release parking brake, set directional lever in F position, and carry out troubleshooting.
HST
Voltage
Between (10) ground
20 30 V

SEN03945-00
40-370
23

Failure code [DXH8KZ] Forward solenoid: Disconnection/Hot short
SEN03945-00

Action code
Failure code
E03
DXH8KZ
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Trouble
Forward solenoid: Disconnection/Hot short

Forward solenoid is not turned ON (HST pressure selector relay does not operate) (when there is
disconnection).
Forward solenoid cannot be turned OFF (Where there is hot short).
Turns output to forward solenoid OFF.
Machine does not travel forward (when there is disconnection).
Machine may start forward suddenly (when there is hot short).
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
function.
Causes


(Internal defect)
Defective diode
2
(Internal defect)
T01 (male)
Resistance
Between (1) (2)
15 30 z
Min. 1 Mz

Between T01A (male) (1) (2)
Possible causes
and standard
value in normal
state
No continuity

3
nector)
ground
Resistance
Max. 1 z
Resistance
Max. 1 z

4
Voltage Max. 1 V
a Prepare with starting switch OFF, then start engine and release
parking brake, and carry out troubleshooting.
HST
Between (10)
ground
40-370
24
Directional lever
position
Voltage
F (Forward)
20 30 V
Other than above
Max. 1 V

SEN03945-00
40-370
25

Failure code [J141N1] Steering pump: Overrun alarm
SEN03945-00
Failure code [J141N1] Steering pump: Overrun alarm

Action code
Failure code
E02
J141N1
Trouble
Steering pump: Overrun alarm

Contents of
trouble
Steering pump speed exceeded alarm operation set value.
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
Steering pump may be broken (If it is broken, machine may not steer).
Advance alarm is turned ON before this code is displayed.
If steering pump speed decreases below alarm reset value, system resets itself.
Causes
1 Steering pump overrun
a Give operator instructions to use engine in range where alarm is

not turned ON.
Failure code [M100N1] HST pump: Overrun alarm

Action code
Failure code
E02
M100N1
Contents of
trouble
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
40-370
26
Trouble
HST pump: Overrun alarm

HST pump speed exceeded alarm operation set value.

HST pump may be broken (If it is broken, machine cannot travel).

If HST pump speed decreases below alarm reset value, system resets itself.
Causes
1 HST pump overrun

not turned ON.

Failure code [M400N1] Motor 1: Overrun alarm
SEN03945-00
Failure code [M400N1] Motor 1: Overrun alarm

Action code
Failure code
E02
M400N1
Trouble
Motor 1: Overrun alarm

Contents of
trouble
HST motor 1 speed exceeded alarm operation set value.
Action of
controller
Problem that
appears on
machine
Related
information
Possible causes
and standard
value in normal
state
HST motor 1 may be broken (If it is broken, machine cannot travel).

If HST motor 1 speed decreases below alarm reset value, system resets itself.
Causes
1 HST motor 1 overrun

not turned ON.
40-370
27
SEN03945-00

2008 KOMATSU
All Rights Reserved
40-370
28
SEN03946-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
40 Troubleshooting
40
400 Troubleshooting of electrical system

(E-mode)
E-1 Engine does not start ............................................................................................................................... 4
E-2 Preheater does not operate normally ..................................................................................................... 12
E-3 Travel speed is low or high..................................................................................................................... 16
E-4 ECSS does not operate.......................................................................................................................... 22
E-5 ECSS keeps operating ........................................................................................................................... 25
E-6 Defective boom kick-out function and cancellation ................................................................................ 28
E-7 Defective bucket positioner function and cancellation............................................................................ 32
E-8 Defective lift arm FLOATING holding function and cancellation............................................................. 36
E-9 Travel direction selection system does not function ............................................................................... 40
E-10 Fan does not reverse ........................................................................................................................... 44
E-11 Fan keeps rotating in reverse ............................................................................................................... 48
E-12 Wiper does not operate ........................................................................................................................ 50
E-13 Windshield washer does not operate ................................................................................................... 54
E-14 Headlamp, clearance lamp and tail lamp do not light up or go off........................................................ 58
E-15 Working lamp does not light up or go off .............................................................................................. 66
E-16 Turn signal lamp and hazard lamp do not light up or go off ................................................................. 72
E-17 Brake lamp does not light or it keeps lighting up .................................................................................. 78
E-18 Backup lamp does not light or it keeps lighting up ............................................................................... 80
E-19 Backup alarm does not sound or it keeps sounding............................................................................. 83
E-20 Horn does not sound or it keeps sounding........................................................................................... 86
E-21 Alarm buzzer does not sound or it keeps sounding ............................................................................. 88
40-400
SEN03946-01
E-22 Air conditioner does not operate or stop............................................................................................... 90

E-23 The KOMTRAX system does not work properly................................................................................... 94
40-400
SEN03946-01
40-400

E-1 Engine does not start
SEN03946-01
Contents of
trouble
Related
information
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.
The engine does not start, because the starting motor does not run due to troubles in the starting
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.
Causes
1 Defective battery
Defective battery relay

(Internal defect)
3 Defective fuse

Specific gravity
Min. 1.26
Voltage
Min. 25 V
The battery relay can be judged normal if operating sounds are audible
when the starting switch is operated.
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
cause 18.)
a Prepare with starting switch OFF (with wiring harness connected),
then turn starting switch START and carry out troubleshooting
Starting motor
Possible
causes and
standard value
in normal state
Defective starting motor

(Internal defect)
Voltage
Between terminals B (E30)

and ground
Power supply input
20 30 V
Between terminals C (E21)

and ground
Starting input
20 30 V
If the starting motor does not run even if power supply input, battery
input and starting input is normal, the starting motor is defective.
(Internal defect)
a Prepare with starting switch OFF, then turn starting switch ON and
Wiring harness between alternator terminal R
E02 (female) (1) ground
Voltage
Max. 1 V
a Prepare with starting switch OFF, then carry out troubleshooting with
starting OFF and START each.
L02 (male)
6
(Internal defect)
Defective multifunction
lever switch
7
short circuit)
Position of switch
Resistance
OFF
Min. 1 Mz
START
Max. 1 z
Between (1) and (2)
OFF
Min. 1 Mz
Between (1) and (4)
ON
Max. 1 z
Between (1) and (3)
MF1 (male)
Between (1) and (3)
40-400
FNR (directional)
lever
Voltage
N (Neutral).
20 30 V
Other than above
Max. 1 V

Causes
SEN03946-01

a Prepare with starting switch OFF, then carry out troubleshooting without turning starting switch ON.
Defective directional
switch (Internal defect)
L62 (male)
Between (1) (3)
Switch position
Resistance
N (Neutral)
Max. 1 z
Other than above
Min. 1 Mz
8
Defective directional
selector switch actuation
L63 (male)
Between (3) (4)
Switch position
Resistance
ON (Directional
switch is selected)
Max. 1 z
OFF
(Lever is selected)
Min. 1 Mz
D21 (male)
Possible
causes and
standard value
in normal state
Diode range
Continuity
Measure at (2) in
Defective diodes (D21,
Between (2) and (1)
Continue
diode range.
D22) (Internal defect)
9
a Only when both diodes a Prepare with starting switch OFF, then carry out troubleshooting withare detective
out turning starting switch ON.
D22 (male)
Diode range
Continuity
Between (2) and (1)
Measure at (2) in
diode range.
Continue
10
Defective diodes (D01)

(Internal defect)
D01 (male)
Diode range
Continuity
Between (5) and (1)
Measure at (5) in
diode range.
Continue
Between (6) and (2)
Measure at (6) in
diode range.
Continue
11

(Internal defect)
D03 (male)
Diode range
Continuity
Between (7) and (3)
Measure at (7) in
diode range.
Continue
Between (8) and (4)
Measure at (8) in
diode range.
Continue
12
Defective diode (D10)

(Internal defect)
D10 (male)
Diode range
Continuity
Between (2) (1)
Measure on (2) side

in diode range
40-400

SEN03946-01
Causes

a Prepare with starting switch OFF (with wiring harness connected),
then carry out troubleshooting without turning starting switch ON.
Starting motor safety relay
Defective starting motor

13 safety relay
(Internal defect)
Voltage
Between B-terminal
E20 E-terminal
Power supply input
20 30 V
Between R-terminal E01

(male) (2) E-terminal
Charge input
Max. 1 V
Between S-terminal E01

(male) (1) E-terminal
Starting input
20 30 V
Between C-terminal
E19 E-terminal
Output
20 30 V
If power supply input and starting input are normal but output voltage is
low, starting motor safety relay is defective.
L106 (male)
Resistance
Between (1) and (2)
200 400 z

a Check neutral safety relay unit.
Possible
causes and
standard value
in normal state
Defective neutral safety

14 relay (L106)
(Internal defect)
Neutral safety relay

(L106)
Between (3) (5)
(1) (2)
Resistance
(When relay is ON)
Max. 1 z
Other than above

(When relay is OFF)
Min. 1 Mz
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 defective.
L107 (male), L108 (male)
Resistance
Between (1) and (2)
200 400 z

a Check engine control cut-out relay unit.
Defective engine control
15 cut-out relays (L107,
L108) (Internal defect)
Engine control cut-out

relay (L107), (L108)
Between (3) (5)
(1) (2)
Resistance
(When relay is ON)
Max. 1 z
Other than above

(When relay is OFF)
Min. 1 Mz
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.
40-400

Causes
SEN03946-01

L79 (male)
Resistance
Between (1) and (2)

200 400 z
Defective KOMTRAX
Between (3) and (6)
Min. 1 Mz
16 engine cut-out relay (L79)
(Internal defect)
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.
L102 (male)
Resistance
Between (1) (2)
200 400 z

a Check VIS power supply holding relay
Defective VIS power sup17 ply holding relay (L102)
(Internal defect)
VIS power supply

holding relay (L102)
Between (3) (5)
(1) (2)
Resistance
(When relay is ON)
Max. 1 z
Other than above

(When relay is OFF)
Min. 1 Mz
Possible
causes and
standard value
in normal state
When VIS power supply holding relay (L102) is replaced with another
relay, if condition becomes normal, VIS power supply holding relay is
defective.
harness
18 (Disconnection in wiring
harness or defective contact)
Wiring harness between battery relay R04

starting motor terminal B (E30)
Resistance
Max. 1 z
Between starting motor B-terminal E30 starting

motor safety relay B-terminal E20
Resistance
Max. 1 z
Between starting motor C-terminal E21 starting

motor safety relay C-terminal E19
Resistance
Max. 1 z
Wiring harness between L02 (female) (3) L79

(female) (3)
Resistance
Max. 1 z

(female) (3)
Resistance
Max. 1 z
Wiring harness between L106 (female) (5) E01

(female) (1)
Resistance
Max. 1 z

(female) (1)
Resistance
Max. 1 z

MF1 (female) (3), L63 (female) (3)
Resistance
Max. 1 z
Wiring harness between MF1 (female) (1), L63

(female) (4) ground
Resistance
Max. 1 z

(female) (1), L108 (female) (1)
Resistance
Max. 1 z
Wiring harness between L02 (female) (4) EC2

(female) (2)
Resistance
Max. 1 z
40-400

SEN03946-01
Causes
harness
18 (Disconnection in wiring
harness or defective contact)

Wiring harness between L107 (female) (2), L108
(female) (2) EC2 (female) (33)
Resistance
Max. 1 z
Wiring harness between fuse No. 4 of fuse box

(FS1) L107 (female) (3), L108 (female) (3)
Resistance
Max. 1 z

(female) (5) EC3 (female) (3), (4)
Resistance
Max. 1 z
Wiring harness between EC3 (female) (1), (2)

ground
Resistance
Max. 1 z
Possible
causes and
Ground fault in wiring harstandard value
ness
19
in normal state
Wiring harness between battery relay R04

starting motor terminal B (E30) and ground
Resistance
Min. 1 Mz
Between wiring harness starting motor B-terminal E30 starting motor safety relay B-terminal
E20 and ground
Resistance
Min. 1 Mz
Between wiring harness starting motor C-terminal E21 starting motor safety relay C-terminal
E19 and ground
Resistance
Min. 1 Mz

(female) (3), circuit branch end and ground
Resistance
Min. 1 Mz

(female) (5) and ground
Resistance
Min. 1 Mz
Wiring harness between L106 (female) (5) E01

Resistance
Min. 1 Mz
Between wiring harness L02 (female) (2) L107

(female) (1), L108 (female) (1) and ground
Resistance
Min. 1 Mz
Between wiring harness L02 (female) (4) EC2

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Between wiring harness fuse box (FS1) No. 3

fuse L102 (female) (5) and ground
Resistance
Min. 1 Mz

(female) (2) EC2 (female) (33) and ground
Resistance
Min. 1 Mz
Wiring harness between fuse No. 4 of fuse box

(FS1) L107 (female) (3), L108 (female) (3) and
ground
Resistance
Min. 1 Mz

(female) (5) EC3 (female) (3), (4) and ground
Resistance
Min. 1 Mz
Hot short in wiring harness Wiring harness between L107 (female) (2), L108
20 (Contact with 5V, 24V cir- (female) (2) EC2 (female) (33), alternator terminal R E02 (female) (1) E01 (female) (2),
cuit)
circuit branch end and ground (Note: if hot short
occurs across them, the charging lamp will be
lighted as the starting switch is ON.
40-400
Voltage
Max. 1 V

Causes
SEN03946-01
Possible
causes and
Between EC2 (33) ground
Voltage Max. 1 V
standard value 21 Defective engine controller
Between EC2 (39) ground
Voltage 20 30 V
in normal state
Between EC3 (3), (4) ground
Voltage 20 30 V
Between EC3 (1), (2) ground
Voltage
Max. 1 V
40-400
SEN03946-01

40-400
10

SEN03946-01
40-400
11

E-2 Preheater does not operate normally
SEN03946-01
a) Preheater does not operate

Contents of
trouble
When temperature is low (engine boost air temperature is below 4C), preheater does not operate.
Related
information
If failure codes are displayed, carry out troubleshooting for them first.
Engine boost air temperature can be checked with monitoring function.
(Monitoring code: ENG-18500-CHG TEMP (C))
(Monitoring code: ENG-18501-CHG TEMP (V))
Causes

a Turn starting switch OFF and remove heater relay.
a Check heater relay unit.
Heater relay

(Internal defect)
Between E05 E07A
E06 R90
Resistance
(When relay is ON)
Max. 1 z
Other than above

(When relay is OFF)
Min. 1 Mz
19 25 z
Between E06 R90

Defective intake air heater
2
(Internal defect)

Resistance
Between E07B ground
0.17
0.27 z

a Replace diode (E06A).
Possible
causes and
standard value
in normal state
Condition becomes normal.

Defective diode (E06A)
3
(Internal defect)
Diode (E06A) is defective.
Condition does not become norDiode (E06A) is normal.

mal.
a Measure in diode range.
Between (2) (1)
a Apply (+) side of tester to (2).
Continuity is secured.


4
Wiring harness between E07A E07B
Wiring harness between R11 E05
Resistance
Max. 1 z
Resistance
Max. 1 z

5
Ground fault in wiring harness Between wiring harness E07A E07B and
ground
Between wiring harness R11 E05 and
ground
40-400
12
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

SEN03946-01
40-400
13

SEN03946-01
b) Preheater operates constantly
Contents of
trouble
Preheater operates constantly.
Related
information
If failure code [CA144] or [CA145] is displayed, carry out troubleshooting for it first.
Engine boost air temperature can be checked with monitoring function.
(Monitoring code: ENG-18500-CHG TEMP (C))
(Monitoring code: ENG-18501-CHG TEMP (V))
Causes

a Turn starting switch OFF and remove heater relay.
a Check heater relay unit.
Heater relay

(Internal defect)
Between E05 E07A
E06 R90
Resistance
(When relay is ON)
Max. 1 z
Other than above

(When relay is OFF)
Min. 1 Mz
19 25 z
Between E06 R90

Possible
causes and
standard value
in normal state

2
Between wiring harness EC2 (40) E06 (5)
ResisMin. 1 Mz
and ground
tance
3
Between wiring harness E07A

E07B and ground
When
preheater
is ON
Voltage
20 30 V
When
preheater
is OFF
Voltage
Max. 1 V
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
14

SEN03946-01
40-400
15

E-3 Travel speed is low or high
SEN03946-01
a) Max. speed is 7 km/h or below and speedometer indicates 0 km/h

Contents of
trouble
Travel speed does not increase above 4 7 km/h.

Speedometer of machine monitor keeps indicating 0 km/h during travel.
Related
information
If failure code [DLT3KX] or [DLT4KX] is also displayed, carry out troubleshooting for it first.
Causes

T09
Voltage
Between (1) (2)
4.7 5.3 V
Between (2) ground
Max. 1 V
Defective travel speed sensor a Prepare with starting switch OFF, then start engine, travel at con(Internal defect)
stant speed, and carry out troubleshooting.
T09
Voltage
Between (3) (2)
Below 1 V Above 4 V
Between (4) (2)
Below 1 V Above 4 V

Possible
causes and
standard value
in normal state

T09 (female) (1)
2
or defective contact in connec- T09 (female) (2)
tor)
T09 (female) (3)
T09 (female) (4)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

Ground fault in wiring harness T09 (female) (1) and ground
3
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

4
40-400
16

and ground
Voltage
Max. 1 V

Causes
SEN03946-01

Possible
causes and
standard value
in normal state
HST
Voltage
Between (22) (32)
4.7 5.3 V
Between (32) ground
Max. 1 V
HST
Voltage
Between (26) (32)
Below 1 V Above 4 V
Between (36) (32)
Below 1 V Above 4 V
40-400
17

SEN03946-01
b) When speed range is set to 3rd speed, speed is not limited and max. travel speed is at 4th speed
level
Contents of
trouble
When speed range is set to 3rd speed, speed is not limited and max. travel speed is at 4th speed
level.
Related
information
If failure code [DW26KA] or [DW26KY] is also displayed, carry out troubleshooting for it first.
Causes

troubleshooting.
Replace HST motor 2
with another relay.
Defective HST motor 2 solenoid relay (Internal defect)
Between (3) (5)
Defective HST motor 2 solenoid (Internal defect)
Relay (L103) is
defective.
Condition does not

become normal.
Relay (L103) is
normal.

a Check relay unit.
HST motor 2 solenoid
relay (L103)
Possible
causes and
standard value
in normal state
Condition becomes
normal.
(1) (2)
Resistance
(Relay is ON)
Max. 1 z
Other than above

(Relay is OFF)
Min. 1 Mz

Resistance
15 30
Mz

3

T07 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

L103 (female) (3)
Resistance
Max. 1 z

4
ResisMin. 1 Mz
tance
40-400
18

SEN03946-01
40-400
19

SEN03946-01
c) When speed range is set to 4th speed, max. speed does not increase above 3rd gear speed level
Contents of
trouble
When speed range is set to 4th speed, max. speed does not increase above 3rd gear speed level.
Related
information
If failure code [DW26KA] is also displayed, carry out troubleshooting for it first.
Causes

troubleshooting.
Replace HST motor 2
with another relay
Possible
causes and
standard value
in normal state
Defective HST motor 2 solenoid relay (Internal defect)
Between (3) (5)
40-400
20
Relay (L103) is
defective.
Condition does not

become normal.
Relay (L103) is
normal.

a Check relay unit.
HST motor 2

2
Condition becomes
normal.
(1) (2)
Resistance
(Relay is ON)
Max. 1 z
Other than above

(Relay is OFF)
Min. 1 Mz

Resistance
Max. 1 V

SEN03946-01
40-400
21

E-4 ECSS does not operate
SEN03946-01
Contents of
trouble
When ECSS switch is turned ON, ECSS does not operate.
Related
information
If failure code [D192KY] is also displayed, carry out troubleshooting for it first.
Input state (ON/OFF) from ECSS switch can be checked with monitoring function.
Causes
1

box FS-2

If fuse is broken, circuit probably has ground fault, etc.
(See cause 6.)
troubleshooting.
L09 (male)
Switch position
ON
Max. 1 z
OFF
Min. 1 Mz
(Always)
Min. 1 Mz
Between (5) (6)

2
Defective ECSS switch (Internal defect)
Between (5), (6)

another terminal
Resistance

Resistance
200
400 z
troubleshooting.
Possible
causes and
standard value
in normal state

Replace ECSS solenoid relay (L110) with

another relay.
Condition becomes
normal.
Relay (L110) is
defective.
Condition does not

become normal.
Relay (L110) is
normal.

Resistance

4
(Internal defect)
200
400 z

Resistance
Between F07 (male) (1) (2)
15 30 z


5
40-400
22
Wiring harness between fuse box FS-2, No.

9 L09 (female) (6)
Resistance
Max. 1 z

L25 (female) (5), L110 (female) (1), (3)
Resistance
Max. 1 z

L110 (female) (2)
Resistance
Max. 1 z

F07 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

Causes
SEN03946-01

Between wiring harness fuse box FS-2, No.
9 L09 (female) (6), branch end and ground
Possible
causes and
standard value
in normal state

6
L25 (female) (5), L110 (female) (1), (3),

F07 (female) (1), branch end and ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then turn ECSS switch ON,
start engine, and carry out troubleshooting.
7
Defective machine monitor or

HST controller
L24
Between (5) (6)
Travel speed
Voltage
0 4 km/h
20 30 V
Min. 5 km/h
Max. 1 V
40-400
23
SEN03946-01

40-400
24

E-5 ECSS keeps operating
SEN03946-01
Contents of
trouble
When ECSS switch is turned OFF, ECSS keeps operating.

When ECSS switch is turned ON, ECSS operates even at low travel speed (4 km/h or below).
Related
information
Input state (ON/OFF) from ECSS switch can be checked with monitoring function.
Causes

troubleshooting.
L09 (male)
Switch position
ON
Max. 1 z
OFF
Min. 1 Mz
(Always)
Min. 1 Mz
Between (5) (6)

1
Defective ECSS switch

(Internal defect)
Between (5), (6)

another terminal
Resistance

Resistance
200
400 z
troubleshooting.

Replace ECSS solenoid relay (L110) with

another relay.
Condition becomes
normal.
Relay (L110) is
defective.
Condition does not

become normal.
Relay (L110) is
normal.

Possible
causes and
standard value
in normal state

3
(Internal defect)
Resistance
200
400 z

Between F07 (male) (5) (6)
Resistance
15 30 z


4
Wiring harness between fuse box FS-2, No.

9 L09 (female) (6)
Resistance
Max. 1 z

L25 (female) (5), L110 (female) (1), (3)
Resistance
Max. 1 z

L110 (female) (2)
Resistance
Max. 1 z

F07 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

5
Ground fault in wiring harness Between wiring harness L24 (female) (11)
Resistance
Min. 1 Mz
Reference: If above is defective, ECSS operates when ECSS switch

is turned ON even at low travel speed (4 km/h or below).
40-400
25

SEN03946-01
Causes

a Prepare with starting switch OFF, then turn starting switch ON,
turn ECSS switch OFF, and carry out troubleshooting.

Possible
causes and
standard value
in normal state

L25 (female) (5), L110 (female) (1), (3),
Voltage
Max. 1 V

F07 (female) (1), branch end and ground
Voltage
Max. 1 V
a Prepare with starting switch OFF, then turn ECSS switch ON,
start engine, and carry out troubleshooting.
L24
7

HST controller
Between (5) (6)
Travel speed
Voltage
0 4 km/h
20 30 V
Min. 5 km/h
Max. 1 V
turn ECSS switch OFF, and carry out troubleshooting.
Between L24 (11) ground
40-400
26
Voltage
Max. 1 V

SEN03946-01
40-400
27

E-6 Defective boom kick-out function and cancellation
SEN03946-01

Contents of
trouble
Boom kick-out does not function or cannot be cancelled due to defective boom kick-out proximity
switch system, boom kick-out PPC detent system and lift arm detent relay system.
Related
information
Causes

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

Between L113 (male) (1) and (2)
Resistance
200 400
z
Applies 24V impressed voltage

between L113 (male) (1) (2)
Resistance
Max. 1 z
Does not apply voltage between

L113 (male) (1) (2)
Resistance
Min. 1 Mz

a Solid part check.
Between
L113
(male) (3)
and (5)

a Replace detent active relay (L115) with normal relay.
Possible
causes and
standard value
in normal state

2
Defective detent active relay

(Internal defect)
Resistance
200 400
z

a Solid part check.
a Applies impressed voltage between L115 (male) (1) (2)
Between
L115
(male) (3)
and (5)

Resistance
Max. 1 z

L115 (male) (1) (2)
Resistance
Min. 1 Mz
Prepare with starting switch OFF, then carry out troubleshooting

3
Defective boom kick-out PPC

detent (Internal defect)
Between L36 (male) (1), (2) ground
Resistance
30 50 z
Resistance
Min. 1 Mz

a Interchange lift arm positioner proximity switch (F04) with bucket
positioner proximity switch (F03).
Defective lift arm positioner
4 proximity switch (Internal
defect)
40-400
28
Defective boom kickout proximity switch

F04
Boom kick-out proximity switch F04 is

normal.

Causes
SEN03946-01

Wiring harness discontinuity

5 (Disconnection or defective
contact)
Wiring harness between F04 (female) (A)

and fuse (FS1) (13)
Resistance
Max. 1 z
Wiring harness between F04 (female) (B)

and L113 (female) (2)
Resistance
Max. 1 z
Wiring harness between F04 (female) (C)

and ground
Resistance
Max. 1 z

(3) and L115 (female) (5)
Resistance
Max. 1 z

and fuse FS1 (13)
Resistance
Max. 1 z

Resistance
Max. 1 z

and ground
Resistance
Max. 1 z

L115 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z
a With all the above items, the boom kick-out does not function
Possible
causes and
standard value
in normal state

and L113 (female) (2) and ground
Resistance
Min. 1 Mz

and L36 (female) (1) and ground
Resistance
Min. 1 Mz
a In this case, the boom kick-out detent does not function (lever
returns to neutral)
6
Wiring harness ground fault


and fuse (FS1) (13) and ground
Resistance
Min. 1 Mz

(3) and L115 (female) (5) and ground
Resistance
Min. 1 Mz

and fuse FS1 (13) and ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
a In this case, the fuse is blown and no detents function (lever

returns to neutral)
Hot short-circuiting between
7 harnesses (Contact with 5 V,
24V circuit)

Voltage
Max. 1 V
a In this case, the boom kick-out does not function (lever does not
return to neutral)
(3) L115 (female) (5) and ground
Voltage
Max. 1 V
a In this case, lift arm detent operates even if engine is stopped.
40-400
29

SEN03946-01
Causes
Possible
causes and
standard value
in normal state

raise lift arm to the highest position (kick-out operated), and carry
out troubleshooting.

7 harnesses
(Contact with 5 V, 24V circuit) L113 (female) (2) and ground
Voltage
Max. 1 V
a In this case, boom kick-out detent does not function (lever returns
to neutral).
40-400
30

SEN03946-01
40-400
31

E-7 Defective bucket positioner function and cancellation
SEN03946-01
Contents of
trouble
Bucket positioner does not function or cannot be cancelled due to defective bucket positioner proximity switch system, bucket PPC detent system and bucket detent relay system.
Related
information
Causes

a Replace bucket leveler relay (L114) with normal relay.
a Operate bucket positioner with engine started.
Bucket positioner function is normal.
Bucket positioner does not function.

1
Defective bucket leveler relay

(L114)
Resistance
200 400
z

a Solid part check.
Between
L114
(male) (3)
and (5)

Resistance
Max. 1 z

L114 (male) (1) (2)
Resistance
Min. 1 Mz
a Turn starting switch OFF.

Possible
causes and
standard value
in normal state

(L113)
Relay L115 is
normal.

Resistance
200 400
z

a Solid part check.
Between
L115
(male) (3)
and (5)
3 Defective bucket PPC detent

Resistance
Max. 1 z

L115 (male) (1) (2)
Resistance
Min. 1 Mz

40-400
32
Resistance
30 50 z

Causes
SEN03946-01

a Interchange bucket positioner proximity switch (F03) with lift arm
a Operate bucket positioner with engine started.
Defective bucket positioner

proximity switch
Bucket positioner function is normal.
Defective bucket
positioner proximity
switch F03
Bucket positioner does not function.
Bucket positioner
proximity switch F03
is normal.

Possible
causes and
standard value
in normal state

contact)

and fuse FS1 (13)
Resistance
Max. 1 z

Resistance
Max. 1 z

and ground
Resistance
Max. 1 z

(3), and L115 (female) (5)
Resistance
Max. 1 z

and fuse FS1 (13)
Resistance
Max. 1 z

Resistance
Max. 1 z

and ground
Resistance
Max. 1 z

L115 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z
a With all the above items, the bucket positioner does not function
40-400
33

SEN03946-01
Causes

Resistance
Min. 1 Mz
a In this case, the bucket positioner detent does not function (lever
does not return to neutral)
6 Wiring harness ground fault
Possible
causes and
standard value
in normal state
Resistance
Min. 1 Mz
a In this case, the bucket positioner does not function (lever returns
to neutral)
fuse FS1 (13) and ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

returns to neutral)
Voltage
Max. 1 V
a In this case, the bucket positioner does not function (lever does
not return to neutral)
24 V circuit)

Voltage
Max. 1 V

Voltage
Max. 1 V
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.
Voltage
Max. 1 V
a In this case, bucket positioner detent does not function (lever

returns to neutral).
40-400
34

SEN03946-01
40-400
35

E-8 Defective lift arm FLOATING holding function and cancellation
SEN03946-01
Contents of
trouble
Lift arm FLOATING holding does not function or cannot be cancelled due to defective boom kick-out
proximity switch system, lift arm FLOATING PPC detent system and kick-out proximity switch system.
Related
information
Causes

a Replace boom kick-out relay (L113) with normal relay.
a Operate lift arm FLOATING with engine started.
Lift arm FLOATING function is normal.
Lift arm FLOATING does not function.
a Turn starting switch OFF, then carry out troubleshooting without

turning starting switch ON.
Defective boom kick-out relay

Resistance
200 400
z

Resistance
Max. 1 z

L113 (male) (1) (2)
Resistance
Min. 1 Mz

a Solid part check.
Between
L113
(male) (3)
and (5)

Possible
causes and
standard value
in normal state

2

(Internal defect)
Resistance
200 400
z

a Solid part check.
Between
L115
(male) (3)
and (5)

Resistance
Max. 1 z

L115 (male) (1) (2)
Resistance
Min. 1 Mz
Prepare with starting switch OFF, then carry out troubleshooting

3
Defective lift arm FLOATING

PPC detent (Internal defect)
Resistance
30 50 z
Between L35 (1), (2) ground
Resistance
Min. 1 Mz

a Interchange lift arm positioner proximity switch (F04) with bucket
Defective lift arm positioner
4 proximity switch (Internal
defect)
40-400
36
Defective boom kickout proximity switch

F04
Boom kick-out proximity switch F04 is

normal.

Causes
SEN03946-01


contact)

fuse (FS1) (13)
Resistance
Max. 1 z

L113 (female) (2)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

(3) L115 (female) (5)
Resistance
Max. 1 z

fuse FS1 (13)
Resistance
Max. 1 z

L35 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

L115 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z
a With all the above items, the boom kick-out does not function
Possible
causes and
standard value
in normal state

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
a In this case, the boom kick-out detent does not function (lever
returns to neutral)
6
Wiring harness ground fault


fuse (FS1) (13) and ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
Wiring between harness E02 (female) (1)

Resistance
Min. 1 Mz

returns to neutral)
24V circuit)

Voltage
Max. 1 V
a In this case, the boom kick-out does not function (lever does not
return to neutral)
Wiring between harness L113 (female) (1),
Voltage
Max. 1 V
a In this case, lift arm detent operates even if engine is stopped.
40-400
37

SEN03946-01
Causes
Possible
causes and
standard value
in normal state
40-400
38

operate lift arm FLOATING, and carry out troubleshooting.

Voltage Max. 1 V
7 harnesses
(Contact with 5 V, 24V circuit)
a In this case, lift arm FLOATING detent does not function (lever
returns to neutral).

SEN03946-01
40-400
39

E-9 Travel direction selection system does not function
SEN03946-01
a) When parking brake is released, parking brake indicator of machine monitor keeps lighting.
Contents of
trouble
Machine does not travel forward and reverse because of trouble in parking brake system, forward
solenoid valve system or directional lever system.
Related
information
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.
Input state of directional lever FNR input signal can be checked with indicator lamp or monitoring
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)
Causes

Defective parking brake bot1 tom switch (Malfunction or

wrong positioning)
L47 (male)
Between (1) (2)
Possible
causes and
standard value
in normal state
Parking brake
lever position
Resistance
Bottom
Max. 1 z
Other than above
Min. 1 Mz

Disconnection in wiring harness (Disconnection in wiring Wiring harness between HST (female) (16),
2
or defective contact in connec- L27 (female) (1), (6) (2) L47 (female) (2)
tor)
L47 (female) (1) ground
Resistance
Max. 1 z
Resistance
Max. 1 z

3
40-400
40

(Internal defect)
D02 (male)
Diode range
Continuity
Between (5) (1)
Measure at (5) in
diode range.
Continue
Between (7) (3)
Measure at (7) in
diode range.
Continue

SEN03946-01
40-400
41

SEN03946-01
b) When parking brake is released, parking brake indicator of machine monitor goes off but machine
does not travel forward
Contents of
trouble
Machine does not travel forward because of trouble in parking brake system, forward solenoid valve
system or directional lever system.
Related
information
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.
Input state of directional lever FNR input signal can be checked with indicator lamp or monitoring
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)
Causes


(Internal defect)
Between T01 (male) (1) (2)
Resistance
30 60 z
Between T01 (male) (1), (2) ground
Resistance
Min. 1 Mz

2

(Internal defect)
Between T01 (male) (3) (4)
Resistance
30 60 z
Between T01 (male) (3), (4) ground
Resistance
Min. 1 Mz

L15 (male)
Possible
causes and
standard value
in normal state

lever switch (Internal defect)
Between (1) (2)

Between (1) (3)
Between (1) (4)
FNR (Directional)
lever
Resistance
F (Forward)
Max. 1 z
Other than above
Min. 1 Mz
N (Neutral)
Max. 1 z
Other than above
Min. 1 Mz
R (Reverse)
Max. 1 z
Other than above
Min. 1 Mz
a Prepare with starting switch OFF, then start engine, release parking brake, and carry out troubleshooting.
HST
Between (10)
ground
F (Forward)
20 30 V
Other than above
Max. 1 V
R (Reverse)
20 30 V
Other than above
Max. 1 V
Between (34)
ground
F (Forward)
20 30 V
Other than above
Max. 1 V
N (Neutral)
20 30 V
Other than above
Max. 1 V
R (Reverse)
20 30 V
Other than above
Max. 1 V
Between (15)
ground
42
Voltage
Between (20)
ground
Between (5) ground
40-400
FNR (Directional)
lever

SEN03946-01
40-400
43

E-10 Fan does not reverse
SEN03946-01
Contents of
trouble
When fan manual reverse switch is turned ON, fan does not reverse.
When fan auto-reverse switch is turned ON, fan does not reverse
Related
information
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 monitoring function.
(Monitoring code: HST 93400 FAN REVERSE SW)
(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.
Causes
1

box (FS1)

If fuse is broken, circuit probably has ground fault etc.
without turning starting switch.
L69 (male)
Switch position
Resistance
Manual reverse ON
Max. 1 z
Other than above
Min. 1 Mz
Auto-reverse ON
Max. 1 z
Other than above
Min. 1 Mz
Between (5)
terminal other than
(4) and (6)
Any position
Min. 1 Mz
Between (4), (6) terminal other than (5)
Any position
Min. 1 Mz
Between (1), (3) (2)
Any position
5 20 kz
Any position
Min. 1 Mz
Between (5) (6)
Defective cooling fan auto2 reverse switch (Internal

defect)
Possible
causes and
standard value
in normal state
Between (5) (4)

a Replace relay (L104).
Relay (L104) is defective.
Condition does not become

normal.
Relay (L104) is normal.

3
Defective fan reverse solenoid Between L104 (male) (1) (2)

a Check relay unit.
Fan reverse solenoid
relay (L104)
Between (3) - (5)
Defective fan reverse solenoid

4
(Internal defect)
40-400
44
Resistance
200
400 z
(1) (2)
Resistance
(When relay is ON)
Max. 1 z
Other than above

(When relay is OFF)
Min. 1 Mz

Between R59 (male) (1) (2)
Resistance
30 50 z

Causes
SEN03946-01

Wiring harness between No. 13 in fuse box
(FS1) L69 (female) (5)
Resistance
Max. 1 z

L25 (female) (14)
Resistance
Max. 1 z
Resistance
Max. 1 z
Resistance
Max. 1 z

R59 (female) (1)
Resistance
Max. 1 z
Wiring harness between R59 (female) (2)

ground
Resistance
Max. 1 z
5
or defective contact in connec- L25 (female) (10)
tor)
L104 (female) (3)
Possible
causes and
standard value
in normal state

Between wiring harness No. 13 in fuse box
Ground fault in wiring harness (FS1) L69 (female) (5) and ground
6
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz
a Prepare with starting switch OFF, then start engine, operate cooling fan reverse switch, and carry out troubleshooting.
7

HST controller
HST
Indicator
Voltage
Between (37)
ground
OFF
20 30 V
ON
Max. 1 V
40-400
45
SEN03946-01

40-400
46

SEN03946-01
40-400
47

E-11 Fan keeps rotating in reverse
SEN03946-01
Contents of
trouble
When fan manual reverse switch is turned OFF, fan keeps rotating in reverse.
When fan auto-reverse switch is turned OFF, fan starts rotating in reverse automatically.
Related
information
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 monitoring function.
(Monitoring code: HST 93400 FAN REVERSE SW)
(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.
Causes

without turning starting switch.
L69 (male)
Between (5) (6)
Defective cooling fan auto1 reverse switch (Internal

defect)
Between (5) (4)
Switch position
Resistance
Manual reverse ON
Max. 1 z
Other than above
Min. 1 Mz
Auto-reverse ON
Max. 1 z
Other than above
Min. 1 Mz
Between (5) terminal

other than (4) and (6)
Any position
Min. 1 Mz
Any position
Min. 1 Mz
Between (1), (3) (2)
Any position
5 20 z
Any position
Min. 1 Mz

a Replace relay (L104).
Possible
causes and
standard value
in normal state
Relay (L104) is defective.
Condition does not become

normal.
Relay (L104) is normal.

2
Defective fan reverse solenoid Between L104 (male) (1) (2)

a Check relay unit.
relay (L104)
Between (3) (5)
Resistance
200
400 z
(1) (2)
Resistance
(When relay is ON)
Max. 1 z
Other than above

(When relay is OFF)
Min. 1 Mz

3
40-400
48

Voltage
Max. 1 V

Voltage
Max. 1 V

Voltage
Max. 1 V

Causes
Possible
causes and
standard value
in normal state
SEN03946-01

a Prepare with starting switch OFF, then start engine, operate cooling fan reverse switch, and carry out troubleshooting.

HST controller
HST
Indicator
Voltage
Between (37)
ground
OFF
20 30 V
ON
Max. 1 V
40-400
49

E-12 Wiper does not operate
SEN03946-01
Contents of
trouble
(1) Front wiper does not operate.
Related
information
The front wiper does not operate due to the defective front wiper switch, timer, or wiring harness.
Causes
1

box (FS1)

(See cause 6.)
Defective front wiper motor

(Internal defect)
L57
Front wiper switch
Voltage
Between (6) ground
Constant
20 30 V
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.
Possible
causes and
standard value
in normal state
Defective wiper timer (relay)

(Internal defect)
L48
Front wiper switch
Voltage
Between (3) ground
Constant
20 30 V
Between (4) ground
INT
20 30 V
Between (2) ground
Washer side
20 30 V
INT (If wiper switch is

Repeat 20 to 30 V o
Between (5) ground set in INT, voltage is
0V
output intermittently.)
Defective front wiper switch

(Internal defect)
L05
Voltage
Between (7) ground
20 30 V

L05
Front wiper switch
Resistance
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
Other than above
40-400
50
Min. 1 Mz

Causes
SEN03946-01


5
Possible
causes and
standard value
in normal state

L48 (female) (5)
Resistance
Max. 1 z

L57 (female) (2)
Resistance
Max. 1 z

fuse No. 14 of fuse box (FS1), circuit
branch end
Resistance
Max. 1 z

L57 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z



ground
Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz

Resistance
Min. 1 Mz

ground
Resistance
Min. 1 Mz
40-400
51

SEN03946-01
Contents of
trouble
(2) Rear wiper does not operate.
Related
information
Since the rear wiper switch or wiring harness is defective, the rear wiper does not operate.
Causes

Defective rear wiper motor

1
(Internal defect)
L52
Rear wiper switch
Voltage
Between (1) ground
Constant
20 30 V
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.
Defective rear wiper switch

(Internal defect)
Possible
causes and
standard value
in normal state
L05
Voltage
Between (7) ground
20 30 V

L05
Rear wiper switch
Resistance
Between (7) (9)
ON
Max. 1 z
Between (8) (9)
OFF
Max. 1 z
Other than above
Min. 1 Mz

3

fuse No. 14 of fuse box (FN1)
Resistance
Max. 1 z

L52 (female) (3)
Resistance
Max. 1 z

L52 (female) (2)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

Ground fault in wiring harness branch end and ground
4
40-400
52
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

SEN03946-01
40-400
53

E-13 Windshield washer does not operate
SEN03946-01
Contents of
trouble
Windshield washer does not operate.
Related
information
Since the windshield washer motor, switch, timer (for only front), or wiring harness is defective, the
windshield washer does not operate.
Perform the following troubleshooting when the wiper operates normally. (If the wiper does not operate normally, carry out troubleshooting for E-12 Wiper does not operate first.)
Causes

a Prepare with starting switch OFF, then hold starting switch OFF or
turn it ON and carry out troubleshooting.
Defective front washer motor

(Internal defect)
B07
Front wiper switch
Voltage/Resistance
Between (1) ground
Window washer
operation position
20 30 V
Between (2) ground
Max. 1 z
If voltage and resistance are normal but front washer does not operate, front washer motor is defective.
Defective rear washer motor

(Internal defect)
B06
Rear wiper switch
Voltage/Resistance
Between (1) ground
Window washer
operation position
20 30 V
Between (2) ground
Max. 1 z
If voltage and resistance are normal but rear washer does not operate, rear washer motor is defective.
B07
Front wiper switch
Voltage/Resistance

Possible
causes and
standard value
in normal state
Defective front wiper switch

3
(Internal defect)
L05
Voltage
Between (7) ground
20 30 V

L05 (male)
Washer switch for

front wiper
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz
Constant
Min. 1 Mz
Between (7) (6)

Between (7), (6)
ground

Defective rear wiper switch

4
(Internal defect)
L05
Voltage
Between (7) ground
20 30 V

L05 (male)
Between (7) (10)
Between (7), (10)
ground
40-400
54
Washer switch for

rear wiper
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz
Constant
Min. 1 Mz

Causes
SEN03946-01

Defective wiper timer (relay)

(for only front wiper)
L48
Washer switch for

front wiper
Voltage
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

Possible
causes and
standard value
in normal state

6

B07 (female) (1), L48 (female) (2)
Resistance
Max. 1 z
Wiring harness between L05(female) (7)

fuse No. 14 of fuse box (FS1)
Resistance
Max. 1 z

B06 (female) (1)
Resistance
Max. 1 z
Wiring harness between B07 (female) (2),

B06 (female) (2) ground
Resistance
Max. 1 z

B07 (female) (1), L48 (female) (2), circuit

(Contact with ground circuit) Wiring harness between L05 (female) (7)

B06 (female) (1), circuit branch end and
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
40-400
55
SEN03946-01

40-400
56

SEN03946-01
40-400
57

E-14 Headlamp, clearance lamp and tail lamp do not light up or go off
SEN03946-01
Contents of
trouble
(1) Headlamp, clearance lamp and tail lamp do not light up or go off.
Related
information
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).
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).
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
Causes

Possible
causes and
standard value
in normal state
Defective lamp switch

1
(Internal defect)
58
Lamp switch
Resistance
OFF
Min. 1 Mz
Between (2) (3)
1st line
Min. 1 Mz
2nd line
Max. 1 z
OFF
Min. 1 Mz
1st line
Max. 1 z
2nd line
Max. 1 z
Between (1) (3)

2
connector contact)
40-400
L04 (male)

ground
Resistance
Max. 1 z

SEN03946-01
Contents of
trouble
(2) Either of headlamp (low and high beams) does not light up or go off.
Related
information
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 normally.
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).
Causes
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.)
L120 (male)
2
Resistance
Defective headlamp relay, left

Between (1) (2)
200 400 z
When headlamp relay (L120) is replaced with a relay of the same type,
if the condition becomes normal, the headlamp relay is defective.
Possible
causes and
standard value
in normal state
Defective headlamp relay,

right (L119)
L119 (male)
Resistance
Between (1) (2)
200 400 z

When headlamp relay (L119) is replaced with a relay of the same type,
if the condition becomes normal, the headlamp relay is defective.

(Internal defect)
L04 (male)
Between (2) (3)
Headlamp switch
Resistance
OFF
Min. 1 Mz
1st position
Min. 1 Mz
2nd position
Max. 1 z

L04 (male)
Defective dimmer switch
5
(Internal defect)
Between (5) (3)

Between (4) (3)
Dimmer switch
Resistance
Low
Min. 1 Mz
High
Max. 1 z
Low
Max. 1 z
High
Min. 1 Mz
40-400
59

SEN03946-01
Causes


6

L120 (female) (2)
Resistance
Max. 1 z

box (FS1) L120 (female) (1), (3)
Resistance
Max. 1 z

L25 (female) (1), left FLH (female) (B)
Resistance
Max. 1 z
a Carry out above 3 items when left side does not light.
L119 (female) (2)
Resistance
Max. 1 z

box (FS1) L119 (female) (1), (3)
Resistance
Max. 1 z

right FLH (female) (B)
Resistance
Max. 1 z
a Carry out above 3 items when right side does not light.
ground
Possible
causes and
standard value
in normal state
Resistance
Min. 1 Mz
a Carry out above when left side does not go off.

box (FS1) L120 (female) (1), (3) and
ground
Resistance
Min. 1 Mz

ResisMin. 1 Mz
Ground fault in wiring harness L25 (female) (1), left FLH (female) (B) and
tance
7
(Contact with ground circuit) ground
Resistance
Min. 1 Mz
a Carry out above when right side does not go off.

ground
Resistance
Min. 1 Mz

right FLH (female) (B) and ground
Resistance
Min. 1 Mz
a Carry out above 2 items when right side does not light.
Headlamp switch is OFF
L25 (female) (1), left FLH (female) (B) and Voltage
8
(Contact with 5 V, 24V circuit) ground
a Carry out above when left side does not go off.
right FLH (female) (B) and ground
Voltage
Max. 1 V
Max. 1 V
a Carry out above when left side does not light.
40-400
60

SEN03946-01
Contents of
trouble
(3) Headlamp (low beam) does not light up or go off.
Related
information
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.
Causes
1 Broken bulb

If a specific headlamp does not light up, its bulb may be broken or
may have a defective contact. Check the bulb directly.
L04 (male)

2
(Internal defect)
Possible
causes and
standard value
in normal state
Between (5) (3)

Between (4) (3)

3
Dimmer switch
Resistance
Low
Min. 1 Mz
High
Max. 1 z
Low
Max. 1 z
High
Min. 1 Mz

Wiring harness between FLH (female) (A)
L04 (female) (4)
Resistance
Max. 1 z
Reference: Connector FLH is installed to both right and left sides.

4

Wiring harness between FLH (female) (A)
Resistance
Min. 1 Mz
40-400
61

SEN03946-01
Contents of
trouble
(4) Headlamp (high beam) does not light up or go off.
Related
information
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.
Causes
1 Broken bulb

If a specific headlamp does not light up, its bulb may be broken or
L04 (male)

2
(Internal defect)
Possible
causes and
standard value
in normal state
Between (5) (3)

Between (4) (3)

3
Dimmer switch
Resistance
Low
Min. 1 Mz
High
Max. 1 z
Low
Max. 1 z
High
Min. 1 Mz

Wiring harness between FLH (female) (C)
L04 (female) (5)
Resistance
Max. 1 z

4
Ground fault in wiring harness Wiring harness between FLH (female) (C)
(Contact with ground circuit) L04 (female) (5), circuit branch end and
ground
Resistance
Min. 1 Mz
40-400
62

SEN03946-01
Contents of
trouble
(5) Clearance lamp does not light up or go off.

(6) Tail lamp does not light up or go off.
Related
information
Defective switch, lamp, or wiring harness of the clearance lamp or tail lamp system.
When the headlamp and turn signal lamp light up.
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).
Causes
1 Broken bulb
2
Defective fuses No. 10 and

No. 11 of fuse box (FS2)

If a specific lamp does not light up, its bulb may be broken or may
have a defective contact. Check the bulb directly.
(See cause 5.)
L117 (male)
Resistance
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 defective.
Defective small lamp relay,

right (L118) (Internal defect)
Possible
causes and
standard value
in normal state
L118 (male)
Resistance
Between (1) (2)
200 400 z

When small lamp relay (L118) is replaced with a relay of the same
type, if the condition becomes normal, the small lamp relay is defective.

(Internal defect)
L04 (male)
Between (1) (3)
Lamp switch
Resistance
OFF
Min. 1 Mz
1st position
Max. 1 z
2nd position
Max. 1 z


6

L117 (female) (2), L118 (female) (2)
Resistance
Max. 1 z

box (FS2) L117 (female) (1), (3)
Resistance
Max. 1 z
box (FS2) L118 (female) (1), (3)
Resistance
Max. 1 z
a Carry out above when right side does not light.

FLC1 (female) (A), R22 (female) (6)
Resistance
Max. 1 z

FLC (female) (A), R23 (female) (6)
Resistance
Max. 1 z
40-400
63

SEN03946-01
Causes

L117 (female) (2), L118 (female) (2) and
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
a Carry out above when lamp does not go off.

ground
7
Possible
causes and
standard value
in normal state
Ground fault in wiring harness a Carry out above when left side does not go off.
(Contact with ground circuit) Wiring harness between fuse No. 11 of fuse
Resisbox (FS2) L118 (female) (1), (3) and
tance
ground
Min. 1 Mz
a Carry out above when right side does not light.

FLC1 (female) (A), R22 (female) (6) and
ground
Resistance
Min. 1 Mz

FLC (female) (A), R23 (female) (6) and
ground
Resistance
Min. 1 Mz

Headlamp switch is OFF
L117 (female) (2), L118 (female) (2), circuit branch end and ground

8
FLC1 (female) (A), R22 (female) (6), circuit branch end and ground
FLC (female) (A), R23 (female) (6), circuit branch end and ground
40-400
64
Voltage
Max. 1 V
Voltage
Max. 1 V
Voltage
Max. 1 V

SEN03946-01
40-400
65

E-15 Working lamp does not light up or go off
SEN03946-01
Contents of
trouble
(1) Front working lamp does not light up or go off.
Related
information
The switch, lamp, or wiring harness of the front working lamp system is defective
When the rear working lamp is normal
If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.
Causes
1 Broken bulb
2

box (FS2)

If a specific working lamp does not light up, its bulb may be broken
or may have a defective contact. Check the bulb directly.
(See cause 6.)
Defective front working lamp

L122 (male)
Resistance
Between (1) (2)
200 400 z

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.
Possible
causes and
standard value
in normal state

L07 (male)
4
Defective front working lamp

Between (5) (6)

Between (5), (6)
ground
Front working lamp

switch
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz
Constant
Min. 1 Mz


5
40-400
66

L122 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

box (FS2) L07 (female) (6), L122 (female) (3)
Resistance
Max. 1 z

C04 (female) (1), C05 (female) (1)
Resistance
Max. 1 z
Wiring harness between C04 (female) (2),

C05 (female) (2) ground
Resistance
Max. 1 z

Causes
SEN03946-01

6
Possible
causes and
standard value
in normal state
Resistance
Min. 1 Mz
Ground fault in wiring harness Wiring harness between fuse No. 12 of fuse
(Contact with ground circuit) box (FS2) L07 (female) (6), L122 (female)
(3) and ground
Resistance
Min. 1 Mz

C04 (female) (1), C05 (female) (1), circuit
Resistance
Min. 1 Mz

Front working lamp switch turned off
7

C04 (female) (1), C05 (female) (1), circuit
Voltage
Max. 1 V
Voltage
Max. 1 V
40-400
67

SEN03946-01
Contents of
trouble
(2) Rear working lamp does not light up or go off.
Related
information
The switch, lamp, or wiring harness of the rear working lamp system is defective.
When the front working lamp is normal
If the clearance lamp does not light up or go off either, carry out troubleshooting for the clearance
lamp first.
Causes
1 Broken bulb
2

box (FS2)

If a specific working lamp does not light up, its bulb may be broken
(See cause 6.)
Defective rear working lamp

L123 (male)
Resistance
Between (1) (2)
200 400 z

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.
Possible
causes and
standard value
in normal state

Defective rear working lamp
4 switch
(Internal defect)
L08 (male)
Between (5) (6)
Between (5), (6)
ground
Rear working lamp

switch
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz
Constant
Min. 1 Mz


5
40-400
68

L123 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

box (FS2) L08 (female) (6), L123 (female) (3)
Resistance
Max. 1 z

B01 (female) (1), B02 (female) (1)
Resistance
Max. 1 z
Wiring harness between B01 (female) (2),

B02 (female) (2) ground
Resistance
Max. 1 z

Causes
SEN03946-01

6
Possible
causes and
standard value
in normal state
Resistance
Max. 1 z
Ground fault in wiring harness Wiring harness between fuse No. 13 of fuse
(Contact with ground circuit) box (FS2) L08 (female) (6), L123 (female)
(3) and ground
Resistance
Max. 1 z

B01 (female) (1), B02 (female) (1), circuit
Resistance
Max. 1 z

Front working lamp switch turned off
7

B01 (female) (1), B02 (female) (1), circuit
Voltage
Max. 1 V
Voltage
Max. 1 V
40-400
69
SEN03946-01

40-400
70

SEN03946-01
40-400
71

E-16 Turn signal lamp and hazard lamp do not light up or go off
SEN03946-01
Contents of
trouble
(1) Either of turn signal lamp and hazard lamp does not light up or go off.
Related
information
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,
D-IN-12).
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, DIN-13).
Causes
Defective No.2 and No.10
1
fuses of fuse box (FS1)

(See cause 8.)
L125 (male)
Resistance
Defective hazard relay (L125)

Between (1) and (2)
200 400 z
(Internal defect)
When hazard relay (L125) is replaced with a relay of the same type,
if the condition becomes normal, the hazard relay is defective.
Possible
causes and
standard value
in normal state
Defective hazard/turn signal

3
relay (L124)
L124 (male)
Resistance
Between (5) and (6)
200 400 z
(1), (2), (3), (4) (6)
Min. 1 Mz

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
Defective flasher unit

4
(Internal defect)
Voltage
Between (3) and (1)
20 30 V
Between (4) and (1)
20 30 V and 0 V are indicated

repeatedly.

40-400
72
L49 (male)
Resistance
Min. 1 Mz

Causes
SEN03946-01


5

L49 (female) (3)
Resistance
Max. 1 z

L04 (female) (6), L124 (female) (1), (3)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

Possible
causes and
standard value
in normal state

6
ground
R23 (female) (1) FLC [left] (female) (C) and
ground
R22 (female) (1) FLC [right] (female) C and
ground
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz



Voltage
Max. 1 V

ground
Voltage
Max. 1 V

R23 (female) (1) FLC [left] (female) (C) and
ground
Voltage
Max. 1 V

R22 (female) (1) FLC [right] (female) C and
ground
Voltage
Max. 1 V
40-400
73

SEN03946-01
Contents of
trouble
(2) Turn signal lamp does not light up or go off.
Related
information
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
(right turn signal lamp) can be checked with the monitoring function (Code: MONITOR PANEL 40901,
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).
Causes
1 Broken bulb

If a specific turn signal lamp does not light up, its bulb may be broken or may have a defective contact. Check the bulb directly.
L04 (male)
Defective turn signal lamp

Between (6) (7)

Between (6) (8)
Turn signal lamp

switch
Resistance
Left
Min. 1 Mz
Right
Max. 1 z
Left
Max. 1 z
Right
Min. 1 Mz
a Prepare with starting switch OFF, then check relay unit.

3 Defective hazard relay (L125)
Resistance
Max. 1 z

Possible
causes and
standard value
in normal state
4
Wiring harness between fuse box FS1 No.

10 L125 (female) (6)
Resistance
Max. 1 z

L04 (female) (6)
Resistance
Max. 1 z

R23 (female) (1), FLC (female) (C)
Resistance
Max. 1 z

R22 (female) (1), FLC1 (female) (C)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

ground
Resistance
Max. 1 z
Wiring harness between FLC (female) (B)

ground
Resistance
Max. 1 z
Wiring harness between FLC1 (female) (B)

ground
Resistance
Max. 1 z

5
(Contact with ground circuit) Wiring harness between fuse box FS1 No.
ResisMin. 1 Mz
10 L125 (female) (6) and ground
tance
40-400
74

SEN03946-01
Contents of
trouble
(3) Hazard lamp does not light up or go off.
Related
information
The switch or lamp of the hazard lamp is defective.

Carry out the following troubleshooting when the turn signal lamp flashes normally.
Causes
1

box (FS1)

(See cause 5.)
L125 (male)
Resistance
Defective hazard relay (L125)

Between (1) (2)
200 400 z
2
(Internal defect)
When hazard relay (L125) is replaced with a relay of the same type,
if the condition becomes normal, the hazard relay is defective.
Defective hazard/turn signal

L124 (male)
Resistance
Between (1) (2)
200 400 z

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
in normal state

4
Defective hazard lamp switch

(Internal defect)
L06 (male)
Between (5) (6)
Hazard lamp switch
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz


5

box (FS1) L125 (female) (5)
Resistance
Max. 1 z

Resistance
Max. 1 z

L06 (female) (5)
Resistance
Max. 1 z
Between L124 (female) (6) ground
Resistance
Max. 1 z
Between L125 (female) (2) ground
Resistance
Max. 1 z
Between L49 (female) (4) L124 (female)

(1), (3)
Resistance
Max. 1 z
Between L124 (female) (2) FLC [right] (C),

R23 (1)
Resistance
Max. 1 z
Between L124 (female) (4) FLC [left] (C),

R22 (1)
Resistance
Max. 1 z
40-400
75

SEN03946-01
Causes


Ground fault in wiring harness box (FS1) L125 (female) (5) and ground
6
(Contact with ground circuit) Wiring harness between fuse No. 2 of fuse
Possible
causes and
standard value
in normal state
76
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

When hot short resulted on the wiring harnesses of the following
two circuits
40-400
Resistance


R23 (female) (1), FLC (female) (C), circuit branch end and ground
Voltage
Max. 1 V

R22 (female) (1), FLCL (female) (C), circuit branch end and ground
Voltage
Max. 1 V

L125 (female) (1) L06 (female) (1), (5) and
ground
Voltage
Max. 1 V

SEN03946-01
40-400
77

E-17 Brake lamp does not light or it keeps lighting up
SEN03946-01

Contents of
trouble
Brake lamp does not light or it keeps lighting up.
Related
information
The lamp or wiring harness of the brake lamp system is abnormal.
Causes
1 Broken bulb
2
Defective fuse No.11 of fuse

box (FS1)

If a specific brake lamp does not light up, its bulb may be broken or
(See cause 6.)
Defective brake lamp relay

L121 (male)
Resistance
Between (1) (2)
200 400 z

When brake lamp relay (L121) is replaced with a relay of the same
type, if the condition becomes normal, the brake lamp relay is defective.
L34 (male)
Defective brake lamp switch

4
(Internal defect)
Between (1) (2)

Between (1), (2)
ground
Possible
causes and
standard value
in normal state
Brake pedal
Resistance
Press
Max. 1 z
Released
Min. 1 Mz
Constant
Min. 1 Mz


5

box (FS1) L121 (female) (3), L34
(female) (1)
Resistance
Max. 1 z

L121 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

R22 (female) (5), R23 (female) (5)
Resistance
Max. 1 z
Wiring harness between R22 (female) (4),

R23 (female) (4) ground
Resistance
Max. 1 z

box (FS1) L121 (female) (3), L34
Ground fault in wiring harness (female) (1), circuit branch end and ground
6
R22 (female) (5), R23 (female) (5) and
ground
40-400
78
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

Causes
Possible
causes and
standard value
in normal state
SEN03946-01


R22 (female) (5), R23 (female) (5) and
ground
Voltage
Max. 1 V
Voltage
Max. 1 V
40-400
79

E-18 Backup lamp does not light or it keeps lighting up
SEN03946-01
Contents of
trouble
Backup lamp does not light or it keeps lighting up.
Related
information
The machine monitor monitors the primary circuit of the backup lamp relay for a trouble.
(If hot short occurs in the primary side of the back lamp relay, failure code [D160KY] is indicated.
Carry out troubleshooting for it first.)
If another failure code is displayed, carry out troubleshooting for it first.
Causes
1 Broken bulb
2

box (FS2)

If a specific backup lamp does not light up, its bulb may be broken
(See cause 7.)
L109 (male)
Resistance
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.
Possible
causes and
standard value
in normal state

L126 (male)
Resistance

Between (1) (2)
200 400 z
4 (L126) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit)
relay is defective.
Defective FR pressure select

L101 (male)
Resistance
Between (1) (2)
200 400 z

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
80

Causes
SEN03946-01

box (FS2) L109 (female) (3), (1)
Resistance
Max. 1 z

Resistance
Max. 1 z

L109 (female) (2)
Resistance
Max. 1 z
Reference: Following 4 items are circuits for turning lamp ON with

directional lever in R position.

6
Possible
causes and
standard value
in normal state

Resistance
Max. 1 z

Resistance
Max. 1 z

L126 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z
Reference: Following 4 items are circuits for turning lamp ON when

HST controller outputs signal to reverse solenoid.
14 L101 (female) (3)
Resistance
Max. 1 z

R22 (female) (2) or R23 (female) (2)
Resistance
Max. 1 z

L101 (female) (5)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

ground
Resistance
Max. 1 z

ground
Resistance
Max. 1 z
Wiring harness between fuse box FS1 No. 5

L24 (female) (4), (5)
Resistance
Max. 1 z
Reference: If above wiring harness is disconnected, when directional

switch is set in R and lamp lights and then directional lever or directional switch is set in position other than R, lamp may not go off.
box (FS2) L109 (female) (3), (1) circuit
7
R22 (female) (2), R23 (female) (2), circuit
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz


Voltage
Max. 1 V
40-400
81
SEN03946-01

40-400
82

E-19 Backup alarm does not sound or it keeps sounding
SEN03946-01
Contents of
trouble
Backup alarm does not sound or it keeps sounding.
Related
information
The machine monitor monitors the primary circuit of the backup lamp relay for a trouble.
(If hot short occurs in the primary side of the back lamp relay, failure code [D160KY] is indicated. In
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.
Causes

Defective backup alarm

(Internal defect)
B03
Between (1) (2)

box (FS2)
Gear shift lever
Voltage
20 30 V
Other than R
Max. 1 V
(See cause 7.)
L109 (male)
Resistance
Between (1) (2)

200 400 z
a
Prepare
with
starting
switch
OFF,
then
turn
starting switch ON
relay is defective.
Possible
causes and
standard value
in normal state

L126 (male)
Resistance

Between (1) (2)
200 400 z
4 (L126) (Internal disconnection a Prepare with starting switch OFF, then turn starting switch ON
or short circuit)
relay is defective.
Defective FR pressure select

L101 (male)
Resistance
Between (1) (2)
200 400 z

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
83

SEN03946-01
Causes

box (FS2) L109 (female) (3), (1)
Resistance
Max. 1 z

B03 (female) (1)
Resistance
Max. 1 z

L109 (female) (2)
Resistance
Max. 1 z
Reference: Following 4 items are circuits for turning backup alarm

ON with directional lever in R position.

6
Possible
causes and
standard value
in normal state

Resistance
Max. 1 z

B03 (female) (1)
Resistance
Max. 1 z

L126 (female) (1)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z
Reference: Following 4 items are circuits for turning backup alarm

ON when HST controller outputs signal to reverse solenoid.
14 L101 (female) (3)
Resistance
Max. 1 z

B03 (female) (1)
Resistance
Max. 1 z

L101 (female) (5)
Resistance
Max. 1 z

ground
Resistance
Max. 1 z
Wiring harness between B03 (female) (2)

ground
Resistance
Max. 1 z
Wiring harness between fuse box FS1 No. 5

L24 (female) (4), (5)
Resistance
Max. 1 z
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.
box (FS2) L109 (female) (3), (1) circuit
7
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

40-400
84

Voltage
Max. 1 V

SEN03946-01
40-400
85

E-20 Horn does not sound or it keeps sounding
SEN03946-01

Contents of
trouble
Horn does not sound or it keeps sounding.
Related
information
Causes
1

box (FS2)

(See cause 6.)
Defective horn relay (L116)

2
(Internal defect)
L116 (male)
Resistance
Between (1) (2)
200 400 z

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

(Internal defect)
L13 (male)
Between (1) ground
Horn switch
Resistance
ON
Max. 1 z
OFF
Min. 1 Mz

and carry out troubleshooting. (Disconnect connector and measure on female side)
Possible
causes and
standard value
in normal state
F01, F02
4
Defective horn
(Internal defect)
Between F01 (1) (2)

Between F02 (1) (2)
Horn switch
Voltage
ON
Max. 1 V
OFF
20 30 V
ON
Max. 1 V
OFF
20 30 V
a If horn does not sound normally under above condition, it is

defective.

5
40-400
86

box (FS2) L116 (female) (1), (3)
Resistance
Max. 1 z

L13 (female) (1)
Resistance
Max. 1 z

F01 (female) (1), F02 (female) (1)
Resistance
Max. 1 z

F02 (female) (2) ground
Resistance
Max. 1 z
Wiring harness between steering wheel horn

switch ground
Resistance
Max. 1 z

Causes
SEN03946-01

Possible
causes and
standard value
in normal state

box (FS2) L116 (female) (1), (3), circuit
6
F01 (female) (1), F02 (female) (1), circuit

Resistance
Min. 1 Mz
Resistance
Min. 1 Mz
Resistance
Min. 1 Mz

and carry out troubleshooting while not pressing horn switch.
F01 (female) (1) or F02 (female) (1) and
ground
Voltage
Max. 1 V
40-400
87

E-21 Alarm buzzer does not sound or it keeps sounding
SEN03946-01
Contents of
trouble
Alarm buzzer does not sound or it keeps sounding.
Related
information
Disconnection or ground fault in alarm buzzer output circuit

The output state (ON/OFF) from the alarm buzzer to the machine monitor can be checked with the
monitoring function (Code: MONITOR PANEL 40952, D-OUT-0).
If failure code is indicated, carry out troubleshooting for it first.
Causes
1
Possible
causes and
standard value
in normal state

box FS1
Defective alarm buzzer

(Internal defect)

3

(See cause 4.)
Remove the buzzer then connect +24 V to L46 (male) (1) and
GND to L46 (male) (2).
Alarm buzzer sounds
Alarm buzzer is
normal
Alarm buzzer does not sound
Defective alarm
buzzer

box FS1 L46 (female) (1)
Resistance
Max. 1 z

L24 (female) (14)
Resistance
Max. 1 z

4

box FS1 L46 (female) (1), circuit branch
end and ground
40-400
88
Resistance
Min.
1 Mz
Resistance
Min.
1 Mz
When above 1 4 are normal, failure on the machine monitor can

be suspected.

SEN03946-01
40-400
89

E-22 Air conditioner does not operate or stop
SEN03946-01
Contents of
trouble
Air conditioner does not operate or stop.
Related
information
The following is troubleshooting applicable only to the power supply and GND circuit between the air
conditioner and operator's cab. For troubleshooting of the air conditioner unit, see the Shop Manual
for the air conditioner.
Causes
Defective No.1 and No.2 fuses

of fuse box (FS2) or defective
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 circuit, 15A fuse in the air conditioner and
ground
Resistance
Min.
1 Mz

When fuse No. 1 of fuse box (FS2) is broken
Grounding fault in power

2 supply wiring harness
Possible
causes and
standard value
in normal state

box A compressor clutch relay and ground
Resistance
Min.
1 Mz
Wiring harness between compressor clutch

relay E10 (female) (2) and ground
Resistance
Min.
1 Mz

When 5A fuse of the air conditioner unit main circuit is broken
Wiring harness between 5A fuse of air conditioner unit main circuit C48 (female) (7),
pressure switch, blower OFF relay primary
side and ground
Resistance
Min.
1 Mz

When 15A fuse of the air conditioner unit is broken
Wiring harness between 15A fuse of air conditioner unit blower OFF relay and ground
Resistance
Min.
1 Mz
Wiring harness between blower OFF relay

blower motor and ground
Resistance
Min.
1 Mz

C48
Starting switch
Voltage
ON
20 30 V
Defective A/C control panel
Between (7) and (1)
power supply and disconnecOFF
Max. 1 V
3 tion of GND wring harness
(disconnection or defective
ResisMax. 1 z
box (FS2) C48 (female) (7)
tance
Wiring harness between C48 (female) (1)
ground
40-400
90
Resistance
Max. 1 z

Causes
SEN03946-01

Blower OFF relay,
pressure switch
Blower OFF relay
(15A fuse line) and
ground
Blower OFF relay (5A
fuse line of main circuit) and ground
Possible
causes and
standard value
in normal state
Disconnection in wiring harness of relay power supply

4
Pressure switch
(5A fuse line of main
circuit) and ground
Starting switch
Voltage
ON
20 30 V
OFF
Max. 1 V
ON
20 30 V
OFF
Max. 1 V
ON
20 30 V
OFF
Max. 1 V

box (FS2) blower OFF relay (on the 15A
fuse line)
Resistance
Max. 1 z

box (FS2) blower OFF relay (on the 5A fuse
line of main circuit)
Resistance
Max. 1 z

box (FS2) pressure switch (on the 5A fuse
line of main circuit)
Resistance
Max. 1 z
Wiring harness between pressure switch

compressor clutch relay
Resistance
Max. 1 z
40-400
91
SEN03946-01

40-400
92

SEN03946-01
40-400
93

E-23 The KOMTRAX system does not work properly
SEN03946-01

Trouble
Related
information
The KOMTRAX system does not work properly.

If the KOMTRAX system administrator asks you to check whether any defect occurs in the machine
system, carry out the following troubleshooting.
A defect in the KOMTRAX system, if any, does not appear especially as a defective phenomenon.
Cause

L80
1 Defective power supply
Signal
Voltage
Between (39), (40) Constant power sup(37) and (38)

ply
20 30 V
a Turn the starting switch ON, then start engine and carry out troubleshooting.
LED (1)
Normal state
LED-C1
ON

2 ACC signal and alternator R
troubleshooting.
signal
L80
Signal
Voltage
Between (36) and
(37), (38)
Starting switch ACC
20 30 V
Between (28) (37),

(38)
Alternator R
20 30 V
a Turn the starting switch ON, then carry out troubleshooting.
Possible
causes and
standard value
in normal state
Defective starting switch C

3
signal
LED (3)
Normal state
LED-C3
During cranking: Blinking

Other than above: OFF

L80
Signal
Voltage
S-NET
69V
Starting switch C
During cranking:
20 30 V
Other than above:
Max. 1 V
Between (27) and

(37), (38)
a Turn the starting switch ON, and carry out troubleshooting.
Defective CAN connection

state
LED (4)
Normal state
LED-C4
ON

L80 (female)
Signal
Resistance
Between (7) and (8)
CAN
40 80 z

5 Number of unsent mails
LED (7)
Normal state
7 segments
09
40-400
94
Defective GPS positioning

status
LED (8)
Normal state
Dot
ON
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.

LED display
SEN03946-01
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)
40-400
95
SEN03946-01

2009 KOMATSU
All Rights Reserved
40-400
96
SEN03947-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
40 Troubleshooting
40
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
40-500
SEN03947-01
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

Method of using troubleshooting chart
SEN03947-01
This troubleshooting chart determines the location from the problem occurring on the machine and categorizes 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
q
The questions to ask the operator are given
under the problem. If the answer to the question matches the content given, the cause
given after the arrow is the probable
cause.Keeping the content of the questions in
mind, read the matrix and proceed with Step 2
and Step 3 to pinpoint the correct cause.
Step 3. Method of reading matrix

1. Operate the machine when carrying out troubleshooting of the items in the Diagnosis column. If any problems occur as the result of the
troubleshooting, put a check against the item.
a When carrying out the troubleshooting,
check the easier items first. It is not necessary to follow the number order.
[Example]
Example: Steering does not turn

Ask the operator and check the following points.
q
Did the problem suddenly start?
o Related equipment broken
q
Was the steering wheel heavy before?
o Wear of related parts, defective seal
Step 2. Checks before troubleshooting
q
Before measuring the oil pressure or starting
the troubleshooting, confirm the checks before
starting items, check for leakage of oil, or for
loose bolts. This will prevent wasting time
when troubleshooting. The items given under
Checks before troubleshooting are checks
that are particularly important to make about
the condition of the machine before starting the
actual troubleshooting.
Example: Checks before starting troubleshooting
q
Is oil level and type of oil in hydraulic tank correct?
q
Is there any oil leakage from steering valve or
demand valve?
q
Is steering linkage adjusted properly?
No.
2.
Remedys
Diagnosis
Steering does not turn in both directions (left

and right)
Steering turns only in one direction (left or

right)
Steering is heavy when turned in both directions (left and right)
Steering wheel is heavy in one direction (left

or right)
Work equipment moves
Find the matching cause in the Cause column.

In the same way as in Step 2), if a problem is
found, the Q marks on the same line for the
troubleshooting item are the causes. (In Diagnosis item 2 in the same diagram below the
cause is (c) or (e).)
When there is one Q mark:
Carry out troubleshooting for the other items
marked with Q in the same Cause column to
check if the problem occurs, then make
repairs.
When there are two Q marks:
Go to Step 3) to narrow down the cause.
40-500
SEN03947-01
3.

Operate the machine and carry out troubleshooting of the items not checked in Step 1.
Operate the machine in the same way as in
Step 1, and if any problem occurs, put a check
against the item. (In Troubleshooting item 5 in
the diagram below, the problem was reenacted.)
4.
Find the matching cause in the Cause column.

In the same way as in Step 2), if a problem is
found, the Q marks on the same line for the
troubleshooting item are the causes. (In Diagnosis 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 diagram 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
6.
Repeat the operation in Steps 3, 4, and 5 until

the cause is narrowed down to 1 item (1 common item).
a If cause items are 2 or more, continue until
number of items becomes minimum.
7.
Remedy
After narrowing down the common causes,
take the action given in the remedy line.
Marks and remedies in remedy line
: Replace E: Repair A: Adjust C: Clean

SEN03947-01
40-500

Failure code and cause table
SEN03947-01
The travel speed is slow at forward (Reverse is normal)
The travel speed is slow at reverse (Forward is normal)
Q
Q
The traction force is weak at reverse (Forward is normal)
Q
Q
Steering wheel
Brake
Shift range is not shifted
The brake does not work or does not work well
Engine stalls when traveling or engine speed drops excessively
The steering wheel does not turn
Q
Q
The traction force is weak in both forward and reverse
The traction force is weak at forward (Reverse is normal)
Inching valve linkage
Inching valve
Angle stopper control solenoid

valve
Motor body
HST
motor 1
Motor body
Directional solenoid valve
The machine does not start at reverse (Forward is normal)

HST related
Q
Q
Does not travel forward (reverse is normal)

Speed is slow in both forward and reverse
DA valve
Low pressure relief valve

(Charge relief valve)
High pressure cut-off valve
Pump body (Charge pump end)
High pressure relief valve
Pump body (Piston pump end)
Does not travel forward or in reverse
Damper
Failure Code
HST
motor 2
HST pump
Mode selector solenoid valve

(SOL a)
Angle stopper solenoid valve
(SOL b)
Part causing problem
The steering wheel is heavy

There is play in steering wheel or excessive shock
Machine deviates naturally to one side when traveling
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
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)
Work equipment system
Hydraulic drift of the lift arm occurs often

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
The bucket moves slowly or the tilting-back force is insufficient
Q
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
Hydraulic
fan
ECSS
(if equipped)
The control levers of the lift arm and bucket do not move smoothly
and heavy
ECSS does not operate but pitches and bounces
ECSS does not move at all
Fan revolution is abnormal (Fan sound/vibration is abnormally large
or engine overheats)
Fan always revolves in reverse
40-500
Q
Q
Q
Q
Q Q
Q
Q
Q Q
Q Q
Q Q
Q
Q
Q Q
Q
Q
Q Q Q
Q
Q Q Q
Q
H-6
Q
Q Q Q
Q
H-7
Q Q Q
Q Q
H-8
Q Q Q Q Q Q
H-10
H-9
Q Q Q
Q
H-11
Q
H-16
Q Q
H-17
Q
H-18
Q
Q
Q
Q
Q
Q
H-19
Q
Q
Q
Q Q
Q
Q
Q
H-20
H-21
H-22
H-23
H-24
H-25
Q Q
H-26
Q Q
H-27
Q Q Q
H-28
40-500
HST related
H-2
Brake Steering wheel
Q Q
Troubleshooting No.
Charge valve
Fan motor
Fan pump
Accumulator
ECSS solenoid valve
Cushion valve
2-way restrictor valve
Bypass valve
Bucket PPC valve
Lift arm PPC valve
Bucket cylinder
Lift arm cylinder
Suction valve
Suction and safety valve
Bucket spool
Lift arm spool
Axle
Main relief valve
Wheel brake linkage
Brake piston
Brake disc and plate
Slack adjuster
Brake valve
Accumulator charge valve
Tire inflation pressure
Steering cylinder
Safety valve
Relief valve
Priority valve
Orbit-roll
Steering valve
Work equipment system
Q
Brake pump
Work equipment and steering pump
Transfer
Clutch
Clutch solenoid

SEN03947-01
Work equipment
control valve
Q Q Q
H-1
Q Q
H-3
H-4
H-5
H-12
H-13
H-14
H-15

H-1 The machine does not start
H-1 The machine does not start
HST motor 1
j
l m n o
Motor body
Inching valve
Clutch
Clutch solenoid
Others
HST motor 2
i
Motor body
g h
DA valve
Damper
f
Low pressure relief valve (Charge relief valve)
Damper
Inspection before diagnosis

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?
Cause
HST pump
Ask the operator about the following:

q
Has the machine come not start suddenly?
o Breakage of HST pump and motor related
equipment
q
Was there any problem of not traveling before?
o Internal wear of HST pump and motor related
a b c d e
equipment, defective seal
Transfer
SEN03947-01
Diagnosis
E E E E E E E E E E E E E E E
X X X X X X X X X X X X X X X
A
Does not travel forward or in reverse
Q Q Q
Does not travel forward (reverse is normal)
Does not start at reverse (Forward is normal)
Does not travel forward or in reverse, motor makes sound of

rotation
No.
Remedy
40-500
Q Q Q Q Q Q Q Q Q Q Q
Q Q Q

H-2 The travel speed is slow
SEN03947-01
H-2 The travel speed is slow
Clutch
Clutch solenoid
E
X
E
X
E
X
E
X
E
X
E
X
E
X
E
X
A
E
X
E
X
Travel speed is slow in both forward and reverse
The travel speed is slow at forward (Reverse is normal)
The travel speed is slow at reverse (Forward is normal)
Maximum travel speed in both forward and reverse

is approx. 4 km/h
Maximum travel speed in both forward and reverse

is approx. 18 km/h
Abnormal sound comes from motor in both forward

and reverse when travel speed is 10 km/h or more
Inching valve
Angle stopper control solenoid valve
E
X
Motor body
E
X
Angle stopper solenoid valve (SOL b)
E
X
Mode selector solenoid valve (SOL a)
Others
Motor body
E
X
HST
motor 1
E
X
DA valve
Diagnosis
Low pressure relief valve (Charge relief valve)
Remedy
HST motor 2
No.
HST pump

q
Are the oil level in the hydraulic tank and
the oil type appropriate?
q
Is the inching valve linkage adjusting
appropriate?
q
Is the any external oil leak found around
the hydraulic piping, pump and motor?
Cause

q
Did the travel speed suddenly become
slower?
o Breakage of HST pump and motor
related equipment
q
Was there any problem of travel speed
becoming slower before?
o Internal wear of HST pump and
motor related equipment, defective
seal
Q
Q
40-500
SEN03947-01

H-3 The traction force is weak
H-3 The traction force is weak
Inching valve
Clutch solenoid
Clutch
Transfer
E
X
E E E E E E E
X X X X X X X
A
The traction force is weak at forward (Reverse is normal)
The traction force is weak at reverse (Forward is normal)
The traction force is weak in both forward and reverse, but maximum travel speed is reached the line.
10
E E
X X
The traction force is weak in both forward and reverse
40-500
Inclination control solenoid valve
Motor body
Others
Motor body
Remedy
Diagnosis
Cause
HST
HST
HST
pump motor 2 motor 1
No.
When the travel speed is slow, carry out troubleshooting for

H-2 first.

H-4 Engine stalls when traveling or engine speed drops excessively
SEN03947-01
H-4 Engine stalls when traveling or engine speed drops excessively

q
Was there any problem before?
o Dirt in HST pump, motor related equipment
Cause
HST
HST
Others
pump motor 2
E
X
E
X
E
X
Engine stalls when traveling or engine speed drops excessively
Machine moves when the directional lever is at F or R and engine is at Lo
Diagnosis
b
Inclination stopper solenoid valve (SOL b)
Remedy
DA valve

q
Is the any external oil leak found around the hydraulic piping, pump and
motor?
No.
40-500
11
SEN03947-01

H-5 Shift range is not shifted
H-5 Shift range is not shifted

a
a
Cause
If the speed range switch and the monitor display do not match, check
the electrical wiring.
HST
HST
Others
When the travel speed is slow, carry out troubleshooting for H-2 first.
motor 2 motor 1
Shift range is not shifted
40-500
12
Clutch
Diagnosis
Clutch solenoid
Remedy
No.
Inclination stopper solenoid valve (SOL b)
E
X
E
X
E
X
E
X

H-6 The steering wheel does not turn
SEN03947-01
H-6 The steering wheel does not turn
2-way restrictor valve
Emergency steering valve (*1)
Internal defective steering cylinder (Defective piston seal)
Orbit-roll
Diagnosis
Relief valve
Remedy
Spool
No.
Others
E
X
E E E
X X X
Steering wheel does not turn in both directions (left and right)
In condition in Item 1, movement of work equipment is abnormal
In condition in Item 1, movement of work equipment is normal
Steering wheel turns only in one direction (left or right)
Steering wheel is heavy and does not turn
Oil pressure of steering circuit is low or there is no pressure
Emergency steering does not function in both directions (left and right)
Priority valve
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?
Cause
Hydraulic
pump
Steering

o Breakage of steering related equipment
q
Was there previously any symptom, such as heavy steering?
o Internal wear of steering related equipment, defective seal
q
Q
Q
Q
Q
Q
There is a close connection between the steering circuit and work equipment circuit, so if any abnormality 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.
40-500
13
SEN03947-01

H-7 The steering wheel is heavy
H-7 The steering wheel is heavy
Clogging of hydraulic oil return filter, defective bypass valve
Clogging of oil cooler
E
X
E E E E E
X X X X X
A
C C
Steering wheel is heavy when turned in both directions (left and right)
Diagnosis
Steering wheel is heavy when turned in one direction (left and right)
Steering wheel is heavy particularly when engine is running at low

speed
Lift arm lifting speed is slow when engine is running at full speed
Steering wheel is heavy and there is jerking
Hydraulic oil overheats
Oil pressure of steering circuit is low or there is no pressure
Pressure rises in return piping of steering cylinder
14
Spool
Relief valve
Q
40-500
Priority valve
Internal defective steering cylinder (Defective piston seal)
Orbit-roll internal defect
Others
E
X
Check for abnormalities

Measure operating effort of steering wheel and time taken to
turn steering, and check standard judgement value table to
see if there is any abnormality.
Valve
Remedy

Are the oil level in the hydraulic tank and the oil type appropriate?
q
Is there any abnormality in Orbit-roll, steering column linkage?
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?
q
No.
Cause
The steering pump is defective The hydraulic pump is defective

q
Hydraulic
pump
o Breakage of steering related equipment
q
Was there previously any symptom, such as heavy steering?
a
o Internal wear of steering related equipment, defective
seal
Q
Q
Q
Q
Q
Q
Q
Q

H-8 Steering wheel shakes or jerks
SEN03947-01
H-8 Steering wheel shakes or jerks
Cause
Checks before troubleshooting
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?
q
Is there any variation in the tire inflation pressure?
q
Is the steering wheel play correct?
Defect inside Orbit-roll
Defective 2-way restrictor valve
Defect inside steering cylinder (inside surface of cylinder, piston seal, nut, bolt)
Defective cushion valve
E
X
E
X
E
X
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.
No.
Remedy
Diagnosis
Chassis shakes when traveling on rough road surface
Shakes when steering is suddenly turned during operation or travel
Chassis shakes when accelerating during travel operations
Chassis shakes when engine is started
Excessive shock when steering wheel is turned back
Q
Q
Q
Q
H-9 Machine deviates naturally to one side when traveling
Causes: Defective steering

q
Defective operation of safety valve
q
Oil leakage inside steering cylinder
q
Variation in tire inflation pressure
40-500
15
SEN03947-01

H-10 The brake does not work or does not work well
H-10 The brake does not work or does not work well
q
Has the brake come not to work suddenly?
o Breakage of brake equipment
q
Has the brake come not to work gradually?
o Wear of lining and disc, defective seal
When the brake pedal is stepped on, only a little resistance is felt
When the brake pedal is stepped on, a strong resistance is felt
When the brake works, an abnormal noise occurs from the axle
brake
When the four wheels are jacked up, the axle is placed on a table
and the brake is applied at the first forward speed, only a specific
wheel rotates
An airflow is observed in bleeding air from brake circuit, and the

brake returns to normal after the bleeding
Brake oil leaks abnormally from the axle during inspection
Much metal powders are mixed in the axle oil
The brake pedal leg-power and stroke are normal, but the brake
does not work well
The brake does not work often when the engine is stopped
E E E
X X
E
X
E
X
40-500
16
Q
Q
Q
Q
Q
Q
Q
10 The accumulator is not charged, and a buzzer sounds

11 The brake works after some time lag
Defective brake linkage
Diagnosis
Defective brake pump (For charge)
Remedy
Defective operation of accumulator charge valve
Metal contact due to complete wear of brake lining in axle
Check abnormality
Measure the braking force and check referring to the standard value table if the brake does not work practically.
h
Defective seal of accumulator piston, insufficient gas pressure
Defect inside brake valve
Mixing of air in brake circuit
Wear or abnormality of brake lining in axle
E E
X X
Defective slack adjuster
Defective operation of brake piston in axle

Is the oil level in the hydraulic tank appropriate?
q
Is the play of brake pedal appropriate?
q
Oil leak from brake tube and connector, deformation of
tube.
q
Tire air pressure and state of tire tread.
Defective brake piston seal in axle
Cause
a
No.

H-11 The brake is not released or is dragged
SEN03947-01
H-11 The brake is not released or is dragged

q
Has the brake pedal returned completely?
q
Is the parking brake released completely?
No.
Diagnosis
Defective operation of brake piston in axle
Defective slack adjuster
Wear or abnormality of brake lining in axle
Check abnormality
q
Abnormal heat of brake.
q
Does the machine travel smoothly inertia on a level ground?
Defective brake piston seal in axle
Cause
a
Remedy E E E E
X X X X
The brake pedal is released, but the brake is still applied
When the brake pedal is released, oil is drained from the air bleeder, the circuit oil pressure
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
parking brake is released and the tires are rotated by hand but a specific tire hardly rotates
Q
Q
40-500
17
SEN03947-01

H-12 The lift arm does not rise or lower
H-12 The lift arm does not rise or lower
The bucket cannot operate and the lift arm cannot

rise
The bucket operates but the lift arm cannot rise
The lift arm can rise without load but cannot rise
when loaded
The hydraulic pump causes an abnormal noise
Large hydraulic drift of lift arm cylinder
When the engine is at full throttle, the steering opera- Q

tion is heavy and slow
40-500
18
Damage of lift arm cylinder piston seal
Breakage inside valve body (Lift arm spool)
E
X
Defective operation of main relief valve
Defective low-pressure relief valve
Defective work equipment pump
Remedy C E E E
E X X X
Defective steering pump
Defective operation of spool
Diagnosis
Defective HST charge pump
No.

Is the oil level in the hydraulic tank appropriate?
q
Is the stroke of the lift arm control lever appropriate?
q
Is the engine speed appropriate?
q
Clogging of pump suction port or mixing of much air in oil
Cause
q
Has the lift arm come not to work suddenly?
Work
Priority HST PPC
Tank to Pump
equip- Cylinder
o Seizure or breakage of each equipment
valve pump valve
ment valve
Did any abnormal noise occur at the time
(And where)?
a b c d
e
f
g
h
i
j
q
Was there the phenomenon that the lift arm
worked slowly?
o Wear of parts or deformation of spring
E
X
E
X
Q
Q
Q
Q

H-13 The lift arm moves slowly or the lift arm rising force is insufficient
SEN03947-01
H-13 The lift arm moves slowly or the lift arm rising force is insufficient 1
Remedy C E
E X
E
X
E
X
E
X
A
X
E
X
The bucket tilting force and speed are abnormal, and

the lift arm rising speed is slow
The bucket tilting force and speed are normal, and the
lift arm rising speed is slow
When the oil temperature rises in item 1, the lift arm

speed becomes very slow
Large hydraulic drift of lift arm cylinder
The relief oil pressure from the relief valve of the work
equipment valves is low
The relief oil pressure from the relief valve of the work
equipment valves is too high
Q
Q
Q
Q
Damage of lift arm cylinder piston seal
Wear or breakage inside valve body (Lift arm spool)
Defective operation or improper adjustment of main relief valve
Defective low-pressure relief valve
Diagnosis
No.
Defective work equipment pump and steering pump
Check of abnormality
q
Rising force and speed problem are closely
related, and this problem occurs as insufficient rising speed at first. Measure the lift arm rising speed
when the lift arm is loaded and make sure referring
to the criterion table that the speed is abnormal.
Cause
q
Is the stroke of the lift arm control lever appropri- Tank to Priority HST PPC Work equipment
Cylinder
Pump valve pump valve
valve
ate?
Q
Q
40-500
19
SEN03947-01

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

q
Deformation of lift arm cylinder in appearance
Cause
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)
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

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
Does any leaking noise occur inside the lift arm cylinder when hydraulic drift is measured? o The cylinder packing is defective
H-17 The lift arm wobbles during operation
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 vacuum generated inside the cylinder
a
40-500
Frequent hydraulic drifts o The suction valve on the lift arm cylinder rod side is defective
20

H-18 When the control lever is switched from HOLD to RAISE, the lift arm falls temporarily
SEN03947-01
H-18 When the control lever is switched from HOLD to RAISE, the
lift arm falls temporarily
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
40-500
21

H-19 The bucket does not tilt back
SEN03947-01
H-19 The bucket does not tilt back
The lift arm cannot operate and the bucket cannot tilt back
The bucket can lift the machine but cannot tilt

back, or the lift arm operates but the bucket cannot tilt back
The bucket can tilt back without load but cannot

in digging or scooping up
Q Q
Large hydraulic drift of bucket cylinder
When the engine is at full throttle, the steering

operation is heavy and slow
40-500
22
Damage of bucket cylinder piston seal
Q Q
Breakage inside valve body (Bucket spool)
E
X
Cylinder
Defective operation of main relief valve
Work equipment valve
The spool is defective
The low-pressure relief valve is defective
E E
X X
The hydraulic pump is defective
Diagnosis
Remedy C
E
The HST charge pump (which is used as PPC pump, too) is defective
No.
The steering pump is defective

Is the stroke of the bucket and lift arm control levers appropriate?
Cause
q
Has the bucket come not to work suddenly
Priority HST PPC
Tank to Pump
valve pump valve
o Seizure or breakage of each equipment
a b c d
e
f
g
Did any abnormal noise occur at the
time (And where)?
q
Was there the phenomenon that the bucket
worked slowly?
o Wear of parts or deformation of
spring
E
X
A
X
Q Q

H-20 The bucket moves slowly or the tilting-back force is insufficient
SEN03947-01
H-20 The bucket moves slowly or the tilting-back force is insufficient
The lift arm rising force and speed are normal, and the bucket tilting force and speed
are abnormal
When the oil temperature rises in item 1, the

bucket speed becomes worse
The hydraulic pump is causing an abnormal Q

noise
Large hydraulic drift of bucket cylinder
The relief oil pressure from the relief valve of

the work equipment valves is low
The relief oil pressure from the relief valve of

the work equipment valves is too high
Damage of bucket cylinder piston seal
Wear or breakage inside valve body (Bucket spool)
Defective operation of safety valve (With suction valve)

on bucket cylinder bottom side
E
X
Defective operation or improper adjustment of main relief valve
Defective operation of low-pressure relief valve
E
X
The lift arm rising force and speed are

abnormal, and the bucket tilting force and
speed are abnormal
E
X
Work equipment valve Cylinder
The hydraulic pump and the steering pump are defective
Diagnosis
Cause
PPC
valve
Remedy C E
E X
Check of abnormality
q
Make sure in an actual operation that
the tilting-back force is insufficient.
q
Measure the operating speed of the
bucket, and make sure referring to the
criterion value table that the speed is
abnormal
No.

q
Is the stroke of the bucket control lever Tank to Priority HST
Pump valve pump
appropriate?
q
Seizure of work equipment linkage a b
c
d
bushing (Does any abnormal noise
occur?)
A
X
E
X
Q
Q
40-500
23
SEN03947-01

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

q
Deformation of bucket cylinder in appearance
Cause
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 tilting-back force is insufficient.
q
H-22 The bucket cylinder cannot hold down the bucket
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
Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
q
Oil leak from bucket cylinder piston seal
q
H-23 Hydraulic drifts of the bucket occur often

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
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
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
q
H-24 The bucket wobbles during travel with load

(The work equipment valve is set to HOLD)

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

H-25 When the control lever is switched from HOLD to TILT, the bucket falls temporarily
SEN03947-01
H-25 When the control lever is switched from HOLD to TILT, the
bucket falls temporarily
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
q
Refer to the criterion value table and check if the lever operating efforts are large practically.
Cause
PPC
valve
No.
Remedy
Diagnosis
C
E
Becomes heavy in some places during operation regardless of oil pressure and oil temperature
Becomes heavy overall during operation regardless of oil pressure and oil temperature
40-500
25
SEN03947-01

H-27 The ECSS does not operate and machine pitches and bounces
H-27 The ECSS does not operate and machine pitches and bounces
Sensor
Defective travel speed sensor
Remedy
Troubleshooting
Controller
Malfunction of controller
No.
Accumulator
Gas leakage from accumulator or defective seal

Check that the hydraulic tank is filled with oil of a
proper type up to a proper level.
q
Check that the ECSS switch is set properly.
q
Cause
Solenoid
valve
Malfunction of solenoid valve
Check the following points with the operator.

q
Did the machine starts pitching and bouncing suddenly?
o Breakage of related device
Did abnormal sound come out when the machine
started pitching and bouncing? From what part did
the abnormal sound come out?
q
Did the machine starts pitching and bouncing gradually?
o Wear of related device or defective seal
Travel speed to start operation of ECSS (6 km/h) changes

largely
ECSS does not work while machine is loaded
ECSS does not work while machine is empty
Lift arm lowers more than 30 cm at maximum when ECSS

operated while machine is loaded
ECSS does not work at all
40-500
26
Q
Q

H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally large or engine overheats)
SEN03947-01
H-28 Fan revolution is abnormal (Fan sound/vibration is abnormally

large or engine overheats)
Fan hunts
Fan does not revolve
E E E E
X X X X
X
Q
Fan always revolves in reverse
Fan does not revolve in reverse
Note
Q
Q
Lowering of engine performance
Malfunction of controller
Seized forward-reverse selector valve
Malfunction of suction safety valve
Fan speed is low (in fan 100% mode)
Troubleshooting
Remedy C
E
Malfunction of EPC solenoid valve
No.
Seized ON/OFF solenoid valve
Malfunction of relief valve
E E
X X
(Note): If Lowering of engine performance is judged, go to the

troubleshooting for the engine system (S mode).
Others
Defective fan motor
Defective fan pump

q
Check the level and type of the oil in the hydraulic
tank.
q
Check the hydraulic hoses, pump and motor for oil
leakage.
q
Check the fan for damage.
Seized brake circuit selector spool
Check for abnormality

q
Measure the fan speed to check for abnormality.
Clogging or sucked air on pump suction side
Cause
Check the following with the operator.
q
Did the fan start making the abnormal sound sud- Tank to Charge
Fan motor
Pump valve
denly?
o Damage of the devices related to the fan and a b c d e f g h
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 performance or dirt
40-500
27
SEN03947-01

2009 KOMATSU
All Rights Reserved
40-500
28
SEN03948-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
40 Troubleshooting
40

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
40-600
SEN03948-01
Method of using troubleshooting charts

The troubleshooting chart consists of the questions, check items, causes, and troubleshooting 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

SEN03948-01
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.)
40-600
SEN03948-01

<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 gradually], and [Air cleaner clogging caution lamp is flashing].
40-600

SEN03948-01
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.
40-600

S-1 Starting performance is poor
SEN03948-01
General causes why starting performance is poor

q
Defective electrical system
q
Insufficient supply of fuel
q
Insufficient intake of air
q
Improper selection of fuel
a The common rail fuel injection system (CRI) controls the
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 phenomenon does not indicate a trouble, however.
Defective or deteriorated battery
Defective alternator (generator section)
Defective alternator (regulator section)
Defective intake air heater system
Defective injector
Stuck, seized supply pump plunger
Clogged fuel filter, element
Leaking or clogged fuel piping, entry of air
Clogged air breather hole of fuel tank cap
Worn piston ring, cylinder
Defective contact of valve and valve seat
Clogged air cleaner element
Causes
Confirm recent repair history

Degree of use of machine Operated for long period
Q w w
E
w
Engine starts easily when warm
Q Q Q
Non-specified fuel is being used

Replacement of filters has not been carried out according to Operation and
Maintenance Manual
w Q Q
w
Oil must be added more frequently

When engine is preheated or when temperature is low, preheating monitor does not
indicate normally
w
w w
During operation, charge level monitor indicates abnormal charge

w
Dust indicator is red
Air breather hole of fuel tank cap is clogged

Fuel is leaking from fuel piping
When priming pump is operated, it makes no reaction or it is heavy
w Q
Q
w
Starting motor cranks engine slowly
Check items
While engine is cranked

with starting motor,
If air bleeding plug of fuel filter is removed, fuel does not

flow out
w
w
Much fuel returns from the injector
When exhaust manifold is touched immediately after starting engine, temperature of

some cylinders is low
w
Q Q
Engine does not pick up smoothly and combustion is irregular
w
Q w Q
There is hunting from engine (rotation is irregular)

w
Blow-by gas is excessive

q
Inspect air cleaner directly
q q
When compression pressure is measured, it is found to be low
Troubleshooting
When air is bled from fuel system, air comes out
Inspect fuel filter, strainer directly

Carry out troubleshooting according to No-pressure feed by supply pump (*1) in display
of code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not
change
q
q
When starting switch is turned to HEAT, intake air heater mount does not become warm
Is voltage 20 30 V between alternator terminal B and terminal E with
engine at low idle?
Yes
No
40-600
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Replace
Clean
Remedy
Replace
When specific gravity of electrolyte and voltage of battery are measured, they are low
Replace
Questions
Starting performance
Became worse gradually

SEN03948-01
*1: Failure codes [CA559] and [CA2249] in the display of code
40-600

S-2 Engine does not start
Degree of use of machine
Operated for long period
Condition of horn when

starting switch is turned ON
Horn does not sound
Defective starting motor (motor section)
Defective safety relay
E E
Q
Q
Q
w
Makes grating noise
w
w
Soon disengages again
Q Q
Inspect flywheel ring gear directly
There is not voltage (20 30 V) between battery relay terminal B and
terminal E
When terminal B and terminal C of starting switch are connected,

engine starts
When terminal B and terminal C at safety relay outlet are connected,

engine starts
Replace
Replace
Remedy
Replace
q
Replace
When terminal at safety switch and terminal B at starting motor are

connected, engine starts
Replace
Replace
Even if terminal B and terminal C at safety relay outlet are connected,

engine does not start
Carry out troubleshooting in E-mode
Makes rattling noise and does not turn
Speed of rotation is low
40-600
When starting switch is turned to START, starting pinion does not move out
Turn starting switch OFF,

connect cord, and carry out
troubleshooting at ON
When starting switch is turned ON, there is no operating sound from battery relay
When starting switch is

turned to START, starting
pinion moves out, but
Horn volume is low
Battery terminal is loose
Check items
Defective battery relay
Battery electrolyte is low
Troubleshooting
Defective connection of battery terminal
Defective or deteriorated battery
Broken flywheel ring gear
Causes
Correct
Questions
a) Engine does not turn

General causes why engine does not turn
q
Seized parts inside engine
o See S-4 Engine stops during operations
q
Defective electrical system
q
Problem in drive devices on applicable machine side
o Carry out troubleshooting for devices on applicable machine
Defective steering circuit wiring
SEN03948-01

SEN03948-01
b) Engine turns but no exhaust smoke comes out

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 fuel injector
Defective common rail pressure limiter
Defective operation of overflow valve (Does not close)
Defective supply pump IMV (IMA)
Broken supply pump shaft
Seized, abnormally worn feed pump
Clogged fuel filter element
Insufficient fuel in tank
Use of improper fuel
Causes
Questions

E E
w Q w w
Exhaust smoke suddenly stopped coming out (when starting again)

Maintenance Manual
When fuel tank is inspected, it is found to be empty
Q w
Rust and water are found when fuel tank is drained

w
Check items
When fuel filter is removed, there is not fuel in it
Q E
E E
w Q

While engine is cranked with flow out
starting motor,
If spill hose from injector is disconnected, little fuel spills
w Q
w w w
Inspect fuel filter directly

Troubleshooting
Fuel other than specified one is used
Inspect feed pump directly

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
display of code
q
q
Inspect pressure relief valve directly
q
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Replace
Clean
Add
Remedy
Replace
Fuel flows out when pressure limiter return piping is disconnected
40-600


SEN03948-01
c) Exhaust smoke comes out but engine does not start

(fuel is being injected)
General causes why exhaust smoke comes out but engine does
not start
q
Lack of rotating force due to defective electrical system
q
q
q
Defective intake air heater system
Defective coolant temperature sensor, wiring harness
Defective, deteriorated battery
Clogged injector, defective spray
Clogging of fuel filter
Leaking or clogged fuel system, entry of air
Worn dynamic valve system (Valve, rocker lever, etc.)
Causes

E
Suddenly failed to start
E
w
Q Q

Maintenance Manual
w
w

When engine is preheated or when temperature is low, preheating monitor does not
indicate normally
w
w

w Q
w
Check items
Starting motor cranks engine slowly

w
When engine is cranked, abnormal sound is generated around cylinder head

While engine is cranked with flow out
starting motor,
If spill hose from injector is disconnected, little fuel spills
w
q
Inspect dynamic valve system directly

Troubleshooting
Inspect fuel filter directly

Carry out troubleshooting according to No-pressure feed by supply pump (*1) in display
of code
q
q
Coolant temperature gauge does not indicate normally
q
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Replace
Replace
Clean
Remedy
Replace
When starting switch is turned to HEAT, intake air heater mount does not become warm
Replace
Questions
*1: Failure code [CA559] and [CA2249] in the display of code
40-600
10

S-3 Engine does not pick up smoothly
SEN03948-01
S-3 Engine does not pick up smoothly
General causes why engine does not pick up smoothly

q
q
Defective condition of fuel injection
q
q
Controller is controlling in derate mode
(limiting injection rate (output) because of an error in electrical system)
Clogged injector, defective spray
Improper valve clearance
Seized turbocharger, interference of turbocharger
Causes

E E
E
w
Engine pick-up suddenly became worse
E
Q Q
Q
w w w

Replacement of filters has not been carried out according to Operation and Maintenance
Manual
w
w

w

w Q
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some
cylinders is low
Color of exhaust gas is
Q w
w
Blue under light load

w Q
Black
w
w
When engine is cranked, interference sound is generated around turbocharger

High idle speed under no load is normal, but speed suddenly drops when load is applied

q

Troubleshooting
q
q
Inspect valve clearance directly
When turbocharger is rotated by hand, it is found to be heavy

Carry out troubleshooting according to No-pressure feed by supply pump (*1) in display of
code
q
q
Replace
Replace
Correct
Clean
Replace
Adjust
Replace
Clean
Remedy
Correct
When a cylinder is cut out for reduced cylinder mode operation, engine speed does not change
Replace
Questions
40-600
11

S-4 Engine stops during operations
SEN03948-01
S-4 Engine stops during operations
General causes why engine stops during operations

Internal parts of engine seized
q
q
There is overheating
q
Problem in hydraulic pump
Defective starting switch wiring
Defective engine controller power supply wiring
Defective hydraulic pump
Broken auxiliary equipment (pump, compressor, etc.)
Broken supply pump shaft
Broken, seized feed pump
Clogging feed pump gauze filter
Clogging of fuel filter, strainer
Leaking, clogged fuel piping
Broken, seized gear train
Broken, seized crankshaft bearing
Broken, seized piston, connecting rod
Broken dynamic valve system (valve, rocker arm, etc.)
Causes

E E

w w w w
Q w Q w w
w Q
Engine overheated and stopped
Engine stopped slowly
Q Q
There was hunting and engine stopped
w Q
Q Q 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
w
w w

Metal particles are found when oil pan is drained
w w
Does not turn at all
w w
Q Q
Turns in opposite direction
Moves by amount of gear backlash
w
w
Supply pump shaft does not turn
Engine turns, but stops when load is applied to machine

q
Inspect piston, connecting rod directly
Inspect crankshaft bearing directly
Troubleshooting
Inspect gear train directly
Inspect feed pump gauze filter directly
Inspect feed pump directly

Carry out troubleshooting according to No-pressure feed by supply
pump (*1) in display of code
q q
Engine rotates when pump auxiliary equipment (pump, compressor, etc.)

is removed
Check controller power supply wiring

Replace
Replace
Replace
Replace
Clean
Clean
Clean
Correct
Add
Replace
Replace
Replace
Remedy
Replace
Check starting switch wiring
q
q
Correct
Check items
When engine is cranked by

hand
Q Q
Q Q
Carry out troubleshooting in H-mode
Condition when engine

stopped
Questions
Abnormal noise was heard and engine

stopped suddenly
Correct
40-600
12

S-5 Engine does not rotate smoothly
SEN03948-01
S-5 Engine does not rotate smoothly
General causes why engine does not rotate smoothly

q
Air in fuel system
q
Defective speed sensor (Error at degree that it is not indicated)
Defective G speed sensor, wiring harness
Defective Ne speed sensor, wiring harness
Clogged injector, defective spray (dirt in injector)
Causes

E
Q Q
Occurs at a certain speed range

Q
Occurs even when speed is raised
Q Q
Occurs on slopes
Replacement of filters has not been carried out according to Operation and Maintenance Manual
w

Check items
w Q
Troubleshooting
Carry out troubleshooting according to Abnormality in Ne speed sensor (*1) in display of code
q
Replace
Replace
Replace
Add
Remedy
Clean
Carry out troubleshooting according to Abnormality in Bkup speed sensor (*2) in display of code
Replace
Hunting
Q Q Q Q Q
Occurs at low idle
Replace
Questions
*1: Failure code [CA689] in the display of code

*2: Failure code [CA778] in the display of code
40-600
13

S-6 Engine lacks output (or lacks power)
SEN03948-01
S-6 Engine lacks output (or lacks power)

General causes why engine lacks output
q
q
q
q
o See S-14 Coolant temperature becomes too
high (Overheating)
q
(limiting injection rate (output) because of an
error in electrical system)
Clogged fuel spill piping
Defective boost pressure sensor, wiring harness
Defective installation of boost pressure sensor

(air leakage)
Defective drive of injector (signal, solenoid)
Clogged injector, defective spray (dirt in injector)
Leaking, clogged fuel piping
Air leakage from air intake piping
Causes

E
Q w
Suddenly
Q
Gradually
Maintenance Manual
w
Q
w w
w
w

w
Output becomes insufficient after short stop of operation
Black
w
w

Check items
Q Q
w w
w
High idle speed is too high

Q
High idle speed under no load is normal, but speed suddenly drops when load is applied
w w

w Q Q
Q Q
Q Q Q
Q Q
Inspect air intake piping directly
q q q
When boost pressure is measured, it is found to be low
q
q

Troubleshooting
Q
Q
Q Q Q
Inspect fuel piping
Inspect spill port check valve directly

Carry out troubleshooting according to No-pressure feed by supply pump (*1) in
display of code
When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change
q q
q
Inspect boost pressure sensor mount directly

Carry out troubleshooting according to Abnormality in boost pressure sensor (*2)
in display of code
Correct
Replace
Replace
Replace
Replace
Clean
Correct
Replace
Adjust
Replace
Replace
Clean
Correct
Remedy
q
Replace
Power was lost
Replace
Questions

40-600
14

S-7 Exhaust smoke is black (incomplete combustion)
SEN03948-01
S-7 Exhaust smoke is black (incomplete combustion)

General causes why exhaust smoke is black
q
q
q
q
o See S-14 Coolant temperature becomes too high
(Overheating)
q
(limiting injection rate (output) because of an error in
electrical system)
Improper fuel injection pressure
Improper injection timing
Abnormally worn injector
Clogged, seized injector
Crushed, clogged muffler
Leakage of air between turbocharger and cylinder head
Causes

E
Questions
Suddenly became black
Gradually became black
Q
w
Q Q

w

Power was lost
E
Q Q Q
Suddenly
Q
Gradually
Q
Q
Q Q
Q
Muffler is crushed
w
Air leaks between turbocharger and cylinder head, clamp is loosened
Q Q Q
Engine is operated in low-temperature mode at normal temperature
Check items
cylinders is low
Q w
w
Torque converter stall speed or pump relief speed is high (Fuel is injected excessively)
Exhaust noise is abnormal
Q Q Q
Q
Q w
w

q
When turbocharger is rotated by hand, it is fount to be heavy
Troubleshooting
q
q
When muffler is removed, exhaust sound improves

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
display of code
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Correct
Clean
Replace
Remedy
Replace
q q
Confirm with monitoring function
Replace

40-600
15

S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-8 Oil consumption is excessive (or exhaust smoke is blue)

General causes why oil consumption is excessive
q
Abnormal consumption of oil
q
Long-time operation of engine at low idle or high idle
(Do not run engine at idle for more than 20 minutes
continuously)
q
External leakage of oil
q
Wear of parts in lubrication system
Oil leakage from oil drain plug
Oil leakage from oil piping
Oil leakage from oil filter
Oil leakage from oil cooler
Broken oil cooler
Worn, damaged rear oil seal
Broken piston ring
Clogged breather, breather hose
Turbocharger
Worn seal at blower end
Worn seal at turbine end
Worn, damaged valve (stem, guide, seal)
Dust sucked in from intake system
Causes
Oil leakage from oil pan, cylinder head, etc.
SEN03948-01
E E E
E
w
Oil consumption suddenly increased
Oil becomes contaminated quickly
Q Q w
Q
w w w w w
Outside of engine is dirty with oil

w
There are loose piping clamps in intake system
Inside of turbocharger intake outlet pipe is dirty with oil

Q w
There is oil in coolant

w
Oil level in damper chamber is high

w w
Exhaust smoke is blue under light load

Q
Excessive
w w
w
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty abnormally

Troubleshooting
None
q q
Excessive play of turbocharger shaft
Check breather and breather hose directly
q q
Inspect rear oil seal directly
q q
Pressure-tightness test of oil cooler shows there is leakage
q q q q
40-600
16
Replace
Replace
Correct
Replace
Clean
Replace
Replace
Replace
Correct
Remedy
Correct
There is external leakage of oil from engine
Correct
Amount of blow-by gas
Correct
Check items
Inside of turbocharger exhaust outlet pipe is dirty with oil
Correct
Correct
Questions

S-9 Oil becomes contaminated quickly
SEN03948-01
S-9 Oil becomes contaminated quickly
Exhaust smoke is bad
Clogged turbocharger lubrication drain tube
Defective oil filter safety valve
E E E
Metal particles are found when oil filter is drained
Q Q
Inside of exhaust pipe is dirty with oil
Q
w
w

Amount of blow-by gas
Black
Q Q w
Excessive
Q
w
None
q
Excessive play of turbocharger shaft
q q
Check breather and breather hose directly
See S-7
Check items
Clogged oil filter
Engine oil temperature rises quickly
Troubleshooting
Clogged oil cooler
Clogged breather, breather hose
Worn valve, valve guide
Defective seal at turbocharger turbine end
Causes
Inspect oil cooler directly
Inspect oil filter directly
Spring of oil filter safety valve is hitched or broken
Replace
Replace
Clean
Clean
Replace
Replace
Remedy
Replace
Inspect turbocharger lubrication drain tube directly
40-600
Clean
Questions
General causes why oil becomes contaminated quickly

q
Entry of exhaust gas into oil due to internal wear
q
Clogging of lubrication passage
q
q
Use of improper oil
q
Operation under excessive load
17

S-10 Fuel consumption is excessive
S-10 Fuel consumption is excessive
General causes why fuel consumption is excessive

q
Leakage of fuel
q
Defective condition of fuel injection (fuel pressure, injection timing)
q
Excessive injection of fuel
Improper injection timing
Defective operation of injector
Defective spray by injector
Defective common rail pressure
Defective supply pump plunger
Defective fuel supply pump oil seal
Fuel leakage from fuel filter, piping, etc.
Fuel leakage inside head cover
Causes
SEN03948-01
Condition of fuel
consumption
Gradually increased
E E
E
Q
More than for other machines of same model

Q
Q Q
Suddenly increased
There is external leakage of fuel from engine
Combustion is irregular
w
cylinders is low
w
Q
Low idle speed is high
HST stall speed is high
Q Q
White
Remove head cover and inspect directly
Inspect fuel supply pump oil seal directly
Carry out troubleshooting according to No-pressure feed by supply pump (*1) in display of code

Carry out troubleshooting according to Abnormality in coolant temperature sensor (*2) in display
of code
Replace
Replace
Replace
Correct
Correct
Remedy
q
Replace
Replace
Q Q
Black
Correct
Check items
Engine oil level rises and oil smells of diesel fuel
Troubleshooting
Q Q Q
Q
Replace
Questions

40-600
18

S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)
SEN03948-01
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)1
General causes why oil is in coolant
q
Internal leakage in lubrication system
q
Internal leakage in cooling system
Broken hydraulic oil cooler or

power train oil cooler
Broken oil cooler core, O-ring
Holes caused by pitting
Cracks inside cylinder block
Broken cylinder head, head gasket
Causes

Oil level
E E

Q
Suddenly rose
Q
Q Q
Q Q w
There are excessive air bubbles in radiator, coolant spurts back

Hydraulic oil or power train oil on applicable machine side is milky
When hydraulic oil or power train oil is drained, water is found
w
q
Pressure-tightness test of cylinder head shows there is leakage
q q
Inspect cylinder block directly
Replace
Replace
Remedy
Check directly
q

Replace
Check items
Oil level has risen and oil is milky
Troubleshooting
Q Q
Gradually rose
Hard water is being used as coolant
Replace
Questions
40-600
19

S-12 Oil pressure drops
S-12 Oil pressure drops
General causes why oil pressure drops

q
Leakage, clogging, wear of lubrication system
q
Defective oil pressure control
q
Selection of oil by the temperature etc. specified in the Operation
and Maintenance Manual is not observed.
q
Deterioration of oil due to overheating
Leaking, crushed, clogged hydraulic piping
Clogged oil filter
Defective regulator valve
Defective oil pump
Clogged, broken pipe in oil pan
Clogged strainer in oil pan
Coolant, fuel in oil
Lack of oil in oil pan
Worn journal of bearing
Causes
Defective oil level sensor, wiring harness
SEN03948-01
E
Q w
Oil pressure monitor indicates low oil pressure

Q
Non-specified oil is being used
Replacement of filters has not been carried out according to Operation and Maintenance
Manual
w
w
Indicates pressure drop at low idle

Oil pressure monitor
Indicates pressure drop at low, high idle
Indicates pressure drop on slopes
w w w Q
w
Oil level in oil pan is low
Q
w
w
External hydraulic piping is leaking, crushed

w
Oil is milky or smells of diesel oil

Metal particles are found in oil filter
Inspect oil pan strainer, pipe directly
See S-13
Troubleshooting
Check items
Sometimes indicates pressure drop

Oil level monitor indicates oil level drop
Oil pump rotation is heavy, there is play in oil pump

Valve and spring of regulator valve are fatigued, damaged
Inspect oil filter directly
q q
q
q
q
q
40-600
20
Correct
Replace
Adjust
Replace
Clean
Clean
Add
Remedy
Replace
If oil level sensor is replaced, oil level monitor indicates normally
Replace
Questions

S-13 Oil level rises (Entry of coolant or fuel)
SEN03948-01
S-13 Oil level rises (Entry of coolant or fuel)
General causes why oil level rises

q
Coolant in oil (milky)
q
Fuel in oil (smells diluted diesel fuel)
a If oil is in coolant, carry out troubleshooting for S-11 Oil is in coolant
Check items
Defective seal of auxiliary equipment (pump, compressor)
Defects in supply pump
Broken oil cooler core, O-ring
Worn, damaged rear oil seal
E E
Fuel must be added more frequently
Coolant must be added more frequently
There is oil in coolant
Q Q Q Q
Q
w
Oil smells of diesel fuel

Oil is milky
When engine is started, drops of water come from muffler
w
Q
When radiator cap is removed and engine is run at low idle, an abnormal number of bubbles appears, w
or coolant spurts back
Q
Q
Exhaust smoke is white
Oil level in damper chamber is low
Oil level in hydraulic tank of machine is low

q

Troubleshooting
Broken injector, O-ring
Remove injector and inspect O-ring.
q q
Inspect rear oil seal directly
Remove and inspect supply pump directly
40-600
Replace
Replace
Correct
Replace
Replace
Replace
Remedy
Replace
Inspect seal of auxiliary equipment directly
Replace
Questions
Causes
21

S-14 Coolant temperature becomes too high (overheating)
SEN03948-01
S-14 Coolant temperature becomes too high (overheating)

General causes why coolant temperature becomes too
high
q
Lack of cooling air (deformation, damage of fan)
q
Drop in heat dissipation efficiency
q
Problem in coolant circulation system
q
Rise in oil temperature in power train
o Carry out troubleshooting on applicable machine
Rise in power train oil temperature
Defective coolant temperature gauge
Slipping fan belt, worn fan pulley
Defective radiator cap (pressure valve)
Clogged radiator core
Clogged, crushed radiator fins
Defective operation of thermostat
Broken fan pulley bearing
Lack of coolant
Clogged, broken oil cooler
Causes
Questions

Condition overheating
E E
Q w
Sudden overheated
Always tends to overheat
Rises quickly
Radiator coolant level monitor indicates drop of coolant level
Engine oil level has risen, oil is milky
w w Q
Coolant temperature gauge
Q
Q w w
w
w
Does not go down from red range
Fan belt tension is low

w
When fan pulley is turned, it has play

Q Q w
Milky oil is floating on coolant

w
Check items
There are excessive air bubbles in radiator, coolant spurts back
When light bulb is held behind radiator core, no light passes through
Radiator shroud, inside of underguard are clogged with dirt or mud
Coolant is leaking because of cracks in hose or loose clamps
Coolant flows out from radiator overflow hose
Fan belt whines under sudden acceleration

Power train oil temperature enters red range faster than engine coolant
temperature
q q
When operation of thermostat is carried out, it does not open at cracking

temperature
Check directly
Temperature difference between upper and lower tanks of radiator is large
q
q
Temperature difference between upper and lower tanks of radiator is slight
Inspect radiator core directly
When operation of radiator cap is carried out, its cracking pressure is low
Inspect fan belt, pulley directly
40-600
22
Correct
Replace
Correct
Correct
Replace
Replace
Add
Replace
Replace
Replace
Remedy
Replace
When coolant temperature is measured, it is found to be normal
Replace
Troubleshooting
Inspect oil cooler directly

S-15 Abnormal noise is made
SEN03948-01
S-15 Abnormal noise is made
General causes why abnormal noise is made

q
Abnormality due to defective parts
q
Abnormal combustion
q
Air sucked in from intake system
a Judge if the noise is an internal noise or an external
noise before starting troubleshooting.
a The engine is operated in the low-temperature mode
while it is not warmed up sufficiently. Accordingly, the
engine sound becomes a little larger. This does not indicate abnormality, however.
a When the engine is accelerated, it is operated in the
acceleration mode and its sound becomes a little larger
for up to about 3 seconds. This does not indicate abnormality, however.
Improper fuel injection timing (abnormality in coolant

temperature sensor, boost temperature sensor)
Dirt caught in injector
Clogged, seized injector
Deformed cooling fan, loose fan belt, interference of fan belt
Removed, seized bushing
Improper gear train backlash
Excessive wear of piston ring, cylinder
Defective inside of muffler (dividing board out of position)
Broken dynamic valve system (valve, rocker lever)
Interference of turbocharger, seized turbocharger
Leakage of air between turbocharger and cylinder head
Causes

Condition of abnormal noise
Gradually occurred
Q
Q Q
Suddenly occurred
Q
Q

w
Air leaks between turbocharger and cylinder head
w
w
When engine is cranked, beat noise is generated around muffler

Check items

w Q
w

Q w
Black
Q
w

Q
Abnormal noise is loud when engine is accelerated
Q Q

q
When turbocharger is rotated by hand, it is found to be heavy
When muffler is removed, abnormal noise disappears

Troubleshooting
q q
Inspect fan and fan belt directly

When a cylinder is cut out for reduced cylinder mode operation, engine speed does
not change
q q
q
Abnormal noise is heard only when engine is started
Replace
Replace
Correct
Replace
Replace
Adjust
Replace
Replace
Replace
Replace
Remedy
Replace
40-600
Replace
Questions
23

S-16 Vibration is excessive
General causes why vibration is excessive

q
Defective parts (abnormal wear, breakage)
q
Misalignment between engine and chassis
q
Abnormal combustion
a If abnormal noise is made and vibration is excessive, carry out troubleshooting for S-15 Abnormal noise is made, too.
Misalignment between engine and devices on applicable machine side
Loose engine mounting bolts, broken cushions
Improper fuel injection timing (abnormality in coolant temperature

sensor, boost temperature sensor)
Worn camshaft bushing
Improper gear train backlash
Worn main bearing, connecting rod bearing
Stuck dynamic valve system (valve, rocker lever)
Causes
Broken output shaft, parts in damper on applicable machine side
SEN03948-01
Non-specified oil is being used
Oil pressure is low at low idle

Condition of vibration

Q
Suddenly increased
Gradually increased
Vibration occurs at mid-range speed

Q
Vibration follows engine speed

Exhaust smoke is black
Q Q Q
Q
Inspect main bearing and connecting rod bearing directly

Troubleshooting
Inspect camshaft bushing directly
Inspect engine mounting bolts and cushions directly
When alignment is checked, radial runout or facial runout is detected
40-600
24
Adjust
Replace
Replace
Replace
Replace
Replace
Remedy
Replace
Inspect output shaft or inside of damper directly
Replace
Check items
Questions

SEN03948-01
40-600
25
SEN03948-01

2009 KOMATSU
All Rights Reserved
40-600
26
SEN03949-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
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
50-100

How to read this manual
SEN03949-01

1.
(Rev. 2009.01)1
Removal and installation of assemblies

Special tools
q
Special tools which are necessary for
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
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described in the special tool list.
1) 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
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
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 forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of Sketches of
special tools.
q
Part No. of special tools starting with
79 T:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
* *** ****
Removal
q
In Removal section, the work procedures,
precautions and know-how to do the work, and
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for removal
are described as [1], [2] etc. and their part
numbers, part names and quantities are not
described.
q
Various symbols used in Removal section are
explained and listed below.
k : Precautions related to work safety
a : Guidance or precautions for the work
[*1] : This mark shows that instructions or precautions for parts installation work are given in
Installation section.
6 : Amount of oil or coolant to be drained
4:
Weight of part or component
Installation
Unless otherwise instructed, installation of
parts is to be done in the reverse order to
removal.
q
Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which
corresponds to the mark in Removal section.
q
Common tools that are necessary for installation are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
Marks shown in the Installation section stand
for the following.
q
: Precautions related to work safety

: Guidance or precautions for the work
2 : Type of coating material
3 : Tightening torque
: Amount of oil or coolant to be replenished

Various special tools are illustrated for the local
manufacture.
50-100

2.
SEN03949-01
Disassembly and assembly of assemblies

Special tools
q
Special tools which are necessary for disassembly and assembly of parts are
described as A1, X1 etc. and their part
numbers, part names and quantities are
described in the special tool list.
q
Also the following information is described
in the special tool list.
1) 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.
2) Distinction of new and existing special
tools
N:
Tools newly developed for this
model. They have a new part number respectively.
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 forward the
part number of the existing tool.
Blank : Tools already available for other
models. They can be used without
any modification.
3) Circle mark Q in sketch column:
q
The sketch of the special tool is presented in the section of Sketches of
special tools.
q
Part No. of special tools starting with
79 T:
means that they are not available
from Komatsu Ltd. (i.e. tools to be
made locally).
* *** ****
Disassembly
q
In Disassembly section, the work procedures,
the amount of oil and coolant to be drained are
described.
q
Common tools that are necessary for disassembly are described as [1], [2] etc. and
their part numbers, part names and quantities
are not described.
q
The meanings of the symbols used in Disassembly section are as follows.
k

6 : Amount of oil or coolant drained
Assembly
q
In Assembly section, the work procedures,
the amount of oil and coolant to be replenished
are described.
q
Common tools that are necessary for assembly are described as [1], [2] etc. and their
part numbers, part names and quantities are
not described.
q
The meanings of the symbols used in Assembly section are as follows.
k

2 : Type of coating material
3 : Tightening torque
: Amount of oil or coolant to be replenished

q
Various special tools are illustrated for the local
manufacture.
50-100

Coating materials list
SEN03949-01

a
a
The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this manual.
Category
Komatsu
code
Part number
Q'ty
Container
Main features and applications
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions, and cork plugs from coming out.
LT-1B
790-129-9050
20 g
(2 pcs.)
Used for plastic (except polyethylene,

polypropylene, tetrafluoroethylene and vinyl
Polyethylene
chloride), rubber, metal, and non-metal parts
container
which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene Features: Resistance to heat and chemicals.

container Used to fix and seal bolts and plugs.
LT-3
Adhesive
(Rev. 2009.02)1
790-129-9060
Adhesive: 1 kg
(Set of adhesive
Hardener: 500 g
and hardener)
LT-4
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
ThreeBond
1735
Gasket sealant
Used to stick and seal metal, glass, and plastics.
Polyethylene
Used to seal plugs.
container
Tube
Heat-resistant seal used to repair engines.
50 g
Quick-setting adhesive.
Polyethylene Setting time: Within 5 sec. to 3 min.
container Used mainly to stick metals, rubbers, plastics,
and woods.
Quick-setting adhesive.
Quick-setting type.
Polyethylene
(max. strength is obtained after 30 minutes)
container
Used mainly to stick rubbers, plastics, and
metals.
Aron-alpha
201
790-129-9130
2g
Loctite
648-50
79A-129-9110
50 cc
Features: Resistance to heat and chemicals.

Polyethylene
Used for fitted portions used at high temperacontainer
tures.
1 kg
Used to seal various threaded portions, pipe

Polyethylene
joints, and flanges.
container Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-5
790-129-9080
LG-6
790-129-9160
200 g
Tube
Features: Silicon-based heat and cold-resistant sealant.

Used to seal flange surfaces and threaded
portions.
Used to seal oil pan, final drive case, etc.
LG-7
790-129-9170
1 kg
Tube
Features: Silicon-based quick-setting sealant.

Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant.

Used to seal transfer case, etc.
LG-8
ThreeBond
1207B
50-100
790-129-9140
Can
419-15-18131
100 g

Gasket sealant
CateKomatsu code
gory
Molybdenum
disulfide
lubricant
Container
790-129-9310
200 g
Tube
Used for rough surfaces such as the circle gear

top seal which does not need to be clamped,
water resistance of the clearance at the welded
area, etc.
Can be coated with paint.
LG-10
ThreeBond
1206E
790-129-9320
200 g
Tube
Used as lubricant/sealant when the radiator

hoses are inserted.
Can be coated with paint.
LG-11
ThreeBond
1121
790-129-9330
200 g
Tube
Feature: Can be used together with gaskets.

Used for covers of the transmission case and
steering case etc.
ThreeBond
1211
790-129-9090
100 g
Tube
Gasket sealant used to repair engine.
Tube
Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded
portions.
Used to lubricate linkages, bearings, etc.
Can
Spray type
Thin molybdenum disulphide films are made on
metal surfaces to prevent the metals from scuffing each other.
Applicable for the drive shaft splines, needle
bearings, pins and bolts of various links, etc.
Can
Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc.
Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
Feature: Lithium grease with extreme pressure

lubrication performance.
General purpose type.
LC-G
NEVER-SEEZ
09940-00040
09995-00250
SYG2-400LI
SYG2-350LI
SYG2-400LI-A
G2-LI
SYG2-160LI
G0-LI
SYGA-160CNLI
*: For cold district
SYG0-400LI-A (*)
SYG0-160CNLI
(*)
Grease
Q'ty
LG-9
ThreeBond
1206D
LM-P
Seizure
prevention
compound
Part number
SEN03949-01
Molybdenum
SYG2-400M
disulfide grease SYG2-400M-A
LM-G (G2-M)
SYGA-16CNM
SYG2-400T-A
SYG2-16CNT
SYG0-400T-A (*)
*: For cold district SYG0-16CNT (*)
Hyper White
Grease G2-T,
G0-T (*)
SYG2-400B
Biogrease
G2-B, G2-BT (*) SYGA-16CNB
*: For use at high SYG2-400BT (*)
temperature and SYGA-16CNBT
under high load
(*)
200 g
190 g
Used for parts under heavy load.

Caution:
400 g x 10 Bellows-type Do not apply grease to rolling bearings like
swing circle bearings, etc. and spline.
400 g x 20 container
The grease should be applied to work equipment
16 kg
Can
pins at their assembly only, not applied for
greasing afterwards.
400 g
16 kg
400 g
16 kg
Bellows-type
container
Can
Seizure resistance, heat resistance and water

resistance higher than molybdenum disulfide
grease.
Not conspicuous on machine since color is
white.
Bellows-type Since this grease is decomposed by natural baccontainer

teria in short period, it has less effects on microCan
organisms, animals, and plants.
50-100

SEN03949-01
Grease
G2-S
ThreeBond
1855
G2-U-S
ENS grease
Part number
427-12-11871
SUNSTAR
PAINT PRIMER
580 SUPER
SUNSTAR
PAINT PRIMER
435-95
Container
Tube
Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent
deterioration of rubber and plastic parts.
Used for oil seals of the transmission, etc.
2 kg
Can
Feature: Urea (organic system) grease with heat

resistance and long life. Enclosed type.
Used for rubber, bearing and oil seal in damper.
Caution: Do not mix with lithium grease.
20 ml
Glass
container
Used as primer for cab side.

(Using limit: 4 months after date of manufacture)
20 ml
Glass
container
Used as primer for glass side.

20 ml
Glass
container
200 g
417-926-3910
22M-54-27230
Used as primer for painted surface on cab

side.
Used as primer for black ceramic-coated
surface on glass side and for hard polycarbonate-coated surface.
SUNSTAR
GLASS
PRIMER
435-41
22M-54-27240
150 ml
Can
SUNSTAR
SASH PRIMER
GP-402
22M-54-27250
20 ml
Glass
container
Used as primer for sash (Almite).

SUNSTAR
PENGUINE
SEAL 580
SUPER S or
W
417-926-3910
320 ml
Polyethylene
container
S is used for high-temperature season

and W for low-temperature season as
adhesive for glass.
Sika Japan,
Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene
container
Used as adhesive for glass.

SUNSTAR
PENGUINE
SUPER 560
22M-54-27210
320 ml
Ecocart
(Special
container)
SUNSTAR
PENGUINE
SEAL No. 2505
417-926-3920
320 ml
Polyethylene
container
SEKISUI
SILICONE
SEALANT
20Y-54-55130
333 ml
Polyethylene
container
Used to seal front window.

Cartridge
Used to seal joint of glasses.

Translucent white seal.
GE TOSHIBA
SILICONES
TOSSEAL 381
50-100
22M-54-27220
333 ml
Adhesive for cab glass
Caulking material
Adhesive
Primer
SUNSTAR
GLASS
PRIMER 580
SUPER
Q'ty
Adhesive for cab glass
CateKomatsu code
gory
Used as adhesive for glass.

Used to seal joints of glass parts.

Special tool list
SEN03949-01
Special tool list

a
a
Tools with part number 79*T-***-**** means that they are not available from Komatsu Ltd. (i.e. tools to be
made locally).
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
New/Redesign: N ............ Tools newly developed for this model. They have a new part number respectively.
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 forward the part number of the existing tool.
Blank ..... Tools already available for other models. They can be used without any modification.
Tools marked with Q in the sketch column are presented in the sketches of the special tools (See
Sketches of special tools).
Component
Symbol
Part No.
Part name
Necessity
Q'ty
New/Remodel
Sketch
Nature of work, remarks
Engine front oil seal
795-799-6400 Seal puller
t 1
Installation of engine front oil

seal
Engine rear oil seal
2
3

795-799-6700 Puller
t 1
t 1
Installation of engine rear oil seal

Removal of fuel injector
4
5
795-799-1131 Gear
795-799-8150 Remover
t 1
q 1
Positioning of crankshaft
Removal of inlet connector
790-331-1120
q 1
795-790-4510 Gauge
q 1
Angle tightening of bolt

Judgment of cylinder head bolt
length
8
1
791-415-2002 Remover
790-201-2840 Spacer
q 1
t 1
793T-417-1110 Push tool

790-101-5201 Push tool kit
t 1
t 1
Cylinder head assembly,

fuel injector assembly
A
Cylinder head assembly,
engine front oil seal
assembly
Cooling fan assembly
Transfer assembly and D

parking brake assembly
Wrench (Angle)
790-101-5311 Plate
790-101-5221 Grip
Removal of cooling fan

Press fitting of output shaft
Q bearing
1
1
Press fitting of oil seal of parking

brake case
01010-51225 Bolt
793T-417-1120 Push tool
1
t 1
790-101-5221 Grip
01010-81225 Bolt
t 1
t 1
Press fitting of dust seal of parking brake case

Operation test of transfer clutch
799-301-1500 Oil leak tester
t 1
6
7
799-401-3200 Adapter
02789-00315 Cap
t 1
t 1
8
9
799-101-5160 Nipple
790-190-1500 Pump assembly
t 1
t 1
10 790-201-3260 Bolt (12 x 1.75 mm)
q 2
Removal and installation of

parking brake cylinder rod pin
11 792-735-2420 Collar
t 1

parking brake assembly, cage
assembly and front case
Removal of HST motor 1 shaft
12 792-104-1130 Collar
13 790-101-3101 Bearing puller
t 1
q 1
Disassembly of output shaft and

gear assembly
14 790-101-2501 Puller
15 790-102-2900 Puller
q 1
q 1
16 790-201-1320 Spacer
t 1
Disassembly of HST motor 2

gear and bearing assembly
17 790-101-3501 Gear puller
q 1
Removal of HST motor 1 gear

and outer race
Removal of carrier assembly
50-100
Component
Symbol
Part No.
Part name
q 1
Disassembly of HST motor 1

gear and outer race
19 79G-17L-1000 Bar
t 1
20 795-100-1291 Sleeve driver
t 1
Removal of HST motor 1 gear

shaft and bearing
Removal of clutch housing
21 796-430-1110
t 1
Push tool
t 2
Adapter
t 1
Torque wrench
q 1
Press fitting of cage and bearing

Measurement of output shaft
and rotation torque
27 790-434-1470 Push tool
q 1
793T-623-1170 Push tool
t 1
Installation of parking brake and

plate
Press fitting of axle shaft bearQ ing inner race
793T-422-1440 Push tool

793T-422-1410 Seal support
t 1
t 1
Q
Q

01016-50860 Bolt
t 1
t 6
Q Axle shaft oil seal support
793T-659-1110 Push tool

790-201-2750 Spacer
t 1
t 1
793T-422-1430 Holder
t 1
Q Adjustment of axle shaft bearing

shim
t 1
5
Axle housing assembly
6
7
8
790-101-5271
790-101-5221
Plate
Grip
1
1
01010-51225 Bolt
790-101-3101 Bearing puller
1
q 1
790-101-3501 Gear puller

791T-465-1130 Push tool
q 1
t 1
790-201-2670 Plate
t 1
799-501-1120
t 1
Axle shaft bearing inner race
Removal of axle shaft
Removal of axle shaft bearing

Q Removal of ring gear
10 790-445-5980 Guide bar
t 1
Installation of planetary carrier

roll pin
Removal and installation of pinion gear shaft
11 Commercially Dial gauge

available
79A-264-0021
12 or commerPush-pull scale
cially available
q 1
Measurement of planetary carrier end play
q 1
Measurement of housing starting torque
13 799-301-1500 Oil leak tester
t 1
14 797-101-1211
Wrench
t 1
Operation check of clutch piston

Removal and installation of pinion shaft nut
15 793-615-1100
Wrench
t 1
No-load operation torque of limited slip differential
Installation of HST motor 1 gear

shaft and bearing
Installation of front case
t 1
25 791-126-0211
Commercially
26 available
50-100
Disassembly of HST motor 1, 2

gear and bearing assembly
Assembly of HST motor 1 gear
and outer race
t 1
24 79G-05V-1400 Bar
Differential assembly
Transfer assembly and D 22 790-470-1410 Collar

23 796-667-1310 Collar
Necessity
Q'ty
New/Remodel
Sketch

Special tool list
SEN03949-01
Pin
16 790-201-2840 Push tool
t 1
17 797T-423-1320 Push tool
t 1
18 792T-413-1130 Push tool
t 1
Press fitting of pinion shaft bearQ ing

Press fitting of pinion shaft cage
Q oil seal

Special tool list
Symbol
q 3
Installation of brake piston and

check for brake oil leak
20 790-190-1500 Pump assembly

21 799-101-5210 Nipple
t 1
t 1
Check for brake oil leak
22 793T-422-1611 Plate
23 791T-465-1210 Push tool
t 1
t 1
24 790-201-3280 Bolt (14 x 2.0 mm)
q 4
25 790-201-3260 Bolt (12 x 1.75 mm)
q 2
26 791-615-2130 Sleeve
t 1
27 790-101-2501 Puller
t 1
Removal of pinion gear assembly

Removal of carrier bearing
28 79G-05V-1400 Bar
t 1
Removal of differential case

bearing outer race
Commercially
29 available
q 1
Selection of plate thickness
30 Commercially Torque wrench

available
31 791T-630-2230 Push tool
q 1
Measurement of no-load operation torque of sun gear shaft

Q Installation of carrier bearing
32 Commercially
available
q 1
Depth gauge
t 1
Q
Q Removal of shaft
Removal of cage assembly
upper cover and bearing carrier
33 790-201-2830 Spacer
t 1
Measurement of backlash of
bevel gear
Installation of long cage shaft
bearing
34 791-126-0211
t 1
Installation of long cage shaft

assembly
2
3
Part name
19 793-520-2202 Installer
Hydraulic cylinder
assembly
Part No.
Necessity
Q'ty
New/Remodel
Sketch
Component
SEN03949-01
Dial gauge
Adapter
790-502-1003 Repair stand
t 1
790-101-1102 Hydraulic pump

790-102-2303
Wrench assembly
or
790-102-3802 (for steering)
t 1
Disassembly, assembly of
hydraulic cylinder
t 1
Removal, installation of cylinder

head
790-302-1340 Socket (for steering)
t 1
Removal, installation of piston

nut
t 1
790-101-5021
01010-50816
Grip
Bolt
1
1
790-201-1821
Push tool (Lift)
790-201-1831
790-201-1741
Push tool (Bucket)

Push tool (Steering)
1
1

790-101-5021 Grip
5
Press fitting of cylinder head

bushing
t 1
1
01010-50816
790-201-1630
Bolt
Plate (Lift)
1
1
790-201-1640
790-201-1550
Plate (Bucket)
Plate (Steering)
1
1
Installation of dust seal
50-100
Component
Symbol
Hydraulic cylinder
assembly
7
U
Operator's cab glass

(stuck glass)
50-100
10
q 1
796-720-1680 Ring (Lift, Bucket)

07281-01589 Clamp (Lift, Bucket)
q 1
q 1
796-720-1740 Ring (Steering)

07281-00809 Clamp (Steering)
q 1
q 1
790-102-4300 Wrench assembly

(Lift, Bucket)
790-102-4310 Pin
t 1
3 793-498-1110
Part name
790-720-1000 Expander
1 793-498-1120
1 2 793-498-1130
Center hinge pin
Part No.
Necessity
Q'ty
New/Remodel
Sketch

Special tool list
SEN03949-01
t 2
t 2
Magnet
t 2
t 2

790-101-5281 Plate
t 1
1
Grip
Bolt
Installation of piston ring
t 2
Clear plate
Plate
793-498-1210 Lifter (Suction cup)
790-101-5221
01010-51225
1
1
Adjustment of clearance of window glass

Removal, installation of window
glass
Removal of bearing of front
frame lower hinge
793-840-1410 Push tool
t 1
Removal of bearing of front

frame upper hinge
793-840-1420 Push tool
t 1
793-415-1180
t 1
Press fitting of bearing of front

frame upper hinge
Press fitting of bearing of front
frame lower hinge
Push tool

SEN03949-01
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
D2 Push tool
9JF00891
D4 Push tool
9JF00892
50-100
11

SEN03949-01
H1-1 Push tool
Use this tool with tool H1-2 jointed to it.
H1-2 Push tool
Use this tool with tool H1-1 jointed to it.
50-100
12

SEN03949-01
H2 Seal support
H2 Seal support
50-100
13

SEN03949-01
H3 Push tool
9JF00899
H4 Holder
50-100
14

SEN03949-01
H8 Push tool
COW16159
H17 Push tool
50-100
15

SEN03949-01
H18 Push tool
9JF00901
H22 Plate
50-100
16

SEN03949-01
H23 Push tool
H31 Push tool
50-100
17
SEN03949-01

2009 KOMATSU
All Rights Reserved
50-100
18
SEN03950-02
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up

Removal and installation of fuel supply pump assembly ................................................................................ 2
Removal and installation of fuel injector assembly ......................................................................................... 4
Removal and installation of cylinder head assembly .................................................................................... 12
Removal and installation of engine hood assembly ...................................................................................... 24
Removal and installation of radiator.............................................................................................................. 27
Removal and installation of air aftercooler .................................................................................................... 30
Removal and installation of hydraulic oil cooler assembly ............................................................................ 32
Removal and installation of engine assembly ............................................................................................... 34
Removal and installation of engine front oil seal assembly .......................................................................... 40
Removal and installation of engine rear oil seal assembly ........................................................................... 43
Removal and installation of cooling fan and fan motor assembly ................................................................. 46
Removal and installation of fuel tank assembly ............................................................................................ 49
50-200

Removal and installation of fuel supply pump assembly
SEN03950-02
Removal and installation of fuel

supply pump assembly
5.
Disconnect fuel return hose (7) from fuel supply pump (4).
a If mud is sticking, lock (L) may become
stiff. Accordingly, clean the connecting
area.
a Press lock (L) from both sides and pull out
hose (5).
a Plug the disconnected hose to prevent
fuel leakage.
6.
Disconnect fuel supply hose (8) from fuel supply pump (4).
[*1]
7.
Remove boot (9).
8.
Remove the 2 clamps of fuel high-pressure

pipe (10) between the supply pump and common rail.
9.
Disconnect fuel high-pressure pipe (10) from

fuel supply pump (4).
[*2]
a Remove the boot on the common rail side
of high-pressure pipe (10) and loosen the
sleeve nut.
Removal
k
1.
2.
Stop the machine on a level ground and set

the lock bar to the frame to fix the front and
rear frames.
Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
Disconnect the cable from the negative ()
terminal of the battery.
Open and fix right engine side cover (1).
a Check that the cover is locked securely.
Remove fuel prefilter and bracket assembly

(2).
a Fix fuel prefilter and bracket assembly (2)
to the machine with ropes.
3.
Disconnect wiring harness connector CN-CP3

(3) from fuel supply pump (4).
4.
Disconnect fuel filter hoses (5) and (6) from

fuel supply pump (4).
50-200

Removal and installation of fuel supply pump assembly
10. Remove 3 mounting nuts at part (A) and fuel

supply pump assembly (11).
[*3]
SEN03950-02
[*2]
q
How to install high-pressure pipe (10)
1.
Tighten the sleeve nut with the fingers.
2.
Check that the high-pressure pipe is installed

correctly and tighten the sleeve nut to the following torque.
3 Sleeve nut:
35 3.5 Nm {3.57 0.36 kgm}
k Be sure to use the genuine fuel highpressure pipe clamp and strictly
observe the specified tightening
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.
Remove fuel supply pump assembly (11)

and the gear together. The gear does not
have a positioning mark (missing tooth),
etc.
[*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 mounting 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}
Installation
q
Carry out installation in the reverse order to

removal.
a The internal parts of the fuel hose adapter
may be damaged when it is removed.
Accordingly, do not reuse the fuel hose but
use new one when assembling again, as a
rule.
[*1]
Joint bolt: 19.6 29.4 Nm {2.0 3.0 kgm}
Bleeding air
Bleed air from the fuel system. For details, see
Testing and adjusting, Bleeding air from fuel
system.
50-200

Removal and installation of fuel injector assembly
SEN03950-02

injector assembly
Part name
Necessity
Q'ty
New/Remodel
Sketch
Part No.
795-799-6700 Puller
t 1
795-799-1131 Gear
t 1
795-799-8150 Remover
q 1
Remove 4 muffer mounting bolts (2) and (3)

from the left and from the right respectively.
5.
Lift off muffer (4).

a Take care that the muffer will not interfere
with water drain tube (5).
Special tools
Symbol
4.
Muffer assembly: 40 kg
6.
Remove muffer mounting bracket (6) from the

right.
7.
Disconnect engine intake air heater wiring harness terminal CN-E07B (7).
[*1]
Removal
k
k
k
1.

rear frames.
If the radiator coolant temperature is high,
you may scald yourself with the hot coolant. Wait until the coolant is cooled, and
then drain the coolant.
Drain the coolant from the radiator.
6
6
Radiator: Approx. 26 l
2.
Remove the engine hood assembly. For

details, see Removal and installation of
engine hood assembly.
3.
Remove muffer cover (1).
50-200

SEN03950-02
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 (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.
13. Disconnect 3 wiring harness connectors (15).
[*4]
a While pressing the lock of the wiring harness connector with flat-head screwdriver
[1], pull the connector in the direction of
the arrow.
a Move wiring harness (16) toward the
intake manifold.
14. Using hexagonal wrench (width across flats:

3 mm), remove blow-by duct (17).
[*5]
15. Remove 6 mounting nuts (18) and cylinder
head cover (19).
[*6]
50-200

SEN03950-02
16. Remove 6 boots (20).
[*7]
17. Remove 6 high-pressure pipes (21).
[*8]
18. Position the crankshaft according to the following procedure.

1) Remove plug (22) under the starting motor
and set tool A4.
2) Rotate the crankshaft forward (counterclockwise 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 crankshaft 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 cylinder 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
19. Remove the 12 mounting bolts and rocker arm

(23).
a Loosen locknut (24), and then loosen
adjustment screw (25) by 2 3 turns so
that an excessive force will not be applied
to the push rod when the rocker arm is
installed.
20. Remove 12 crossheads (26).

a Record the installed positions and the
shapes of holes (a) and (b) of the crossheads. (When assembling, install each
crosshead to the intake/exhaust valve
from which it was removed.)

SEN03950-02
Do not remove the connector of injector harness from rocker housing unless it is necessary.
21. Remove retaining nuts (27) and 6 inlet connectors (28).

a Before removing, clean the inlet connectors carefully so that mud, etc. sticking
around them will not enter their holes.
a Tool A5 is set for removal of inlet connector (28). (See the special tools list.)
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
23. Remove 2 mounting bolts (31) of fuel injector

assembly (29).
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

SEN03950-02
Installation
a
1.
The internal parts of the fuel hose adapter may

be damaged when it is removed. Accordingly,
do not reuse the fuel hose but use new one
when assembling, as a rule.
When replacing the fuel injector assembly with
new one, be sure to replace the inlet connector
with new one, too.
6)
7)
Apply engine oil (EO30) to O-ring (35) of

inlet connector (28) and the mounting hole
on the cylinder head side.
Insert inlet connector (28) securely, while
setting part (B) to the groove on the cylinder head side.
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 injector (29) alternately.
3 Fuel injector mounting bolt (31):
8.0 0.8 Nm {0.8 0.08 kgm}
10) Tighten retaining nut (27).
50 5 Nm {5.1 0.5 kgm}
4)
5)
Insert fuel injector (29) in the cylinder

head, directing its fuel inlet hole toward
the air intake manifold.
Tighten 2 mounting bolts (31) of fuel injector (29) by 3 4 turns.
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 harnesses
50-200
Wiring harness
color
Cylinder No.
White
1, 3, 5
Black
2, 4, 6

SEN03950-02
q
When the connector of injector harness is removed.

When assembling the injector harness connector (42) to the housing,
apply gasket sealant (LG-7) to the Oring 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
harness assembly.
3 Connector flange mounting bolt
(45): 10 2 Nm {1 0.2 kgm}
Precautions for installing inlet connector

1) When replacing the fuel injector assembly
with new one, be sure to replace inlet connector, 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 filter at rear end (c) of the inlet connector.
3] The O-ring at upper part (d) of the
inlet connector is cracked or deteriorated.
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

SEN03950-02
2.
Crosshead and rocker arm assembly

1) Install the crosshead and rocker arm.
a The shapes of holes (a) and (b) of
each crosshead are different. Accordingly, when reusing the crossheads,
install each of them to the same
intake/exhaust valve in the same
direction as it has been installed.
2) Check that the ball of adjustment screw
(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}
Carry out the following installation in the

reverse order to removal.
[*1]
Wiring harness terminal CN-E07B (7):

4.0 0.6 Nm {0.41 0.06 kgm}
[*2]
3
3
Clamp (8): 7 1 Nm {0.71 0.1 kgm}

Clamp (9): 10.5 0.5 Nm {1.07 0.05 kgm}
[*3]
Engine intake air heater mounting bolt (12a):

24 4 Nm {2.4 0.4 kgm}
[*4]
Install each fuel high-pressure pipe and

wiring harness at least 10 mm apart from
each other.
[*5]
Blow-by duct (17) mounting bolt:

7 2 Nm {0.7 0.2 kgm}
[*6]
Cylinder head cover mounting nut (18):

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-pressure pipe clamps and observe the tightening 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.
50-200
10

1)
2)
3)
SEN03950-02
Temporarily install fuel high-pressure

pipes (36) (41).
3 Sleeve nut:
0.2 0.8 Nm {0.02 0.08 kgm}
Tighten fuel high-pressure pipes (36)
(41) in the following order.
1] Tighten the cylinder head side of fuel
high-pressure pipes (36) and (41).
2] Tighten the common rail side of fuel
high-pressure pipes (37), (38), (39)
and (40).
and (40).
3 Sleeve nut:
35 3.5 Nm {3.6 0.4 kgm}
Install 6 boots (20) to the fuel high-pressure 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.
Bleeding air
system.
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
11

Removal and installation of cylinder head assembly
SEN03950-02

cylinder head assembly
Part name
Necessity
Q'ty
New/Remodel
Sketch
Part No.
795-799-6700 Puller
t 1
795-799-1131 Gear
t 1
795-799-8150 Remover
q 1
790-331-1120 Wrench (angle)
q 1
795-790-4510 Gauge
q 1
Remove 4 muffler mounting bolts (2) on the left

and 4 (3) on the right.
5.
Lift off muffler (4).

a Take care that the muffler will not interfere
with water drain tube (5).
Special tools
Symbol
4.
Muffler assembly: 40 kg
6.
Remove right muffler mounting bracket (6).
7.
Disconnect engine intake air heater wiring harness terminal CN-E07B (7).
[*1]
Removal
k
k
k
1.

rear frames.
6
2.

3.
Remove muffer cover (1).
50-200
12

SEN03950-02
8.
Remove clamps (8) and (9).
[*2]
9.
Remove air hose (10), and intake air inlet

elbow (11) as a set.
10. Remove mounting bolt (12a) and engine intake

air heater (electrical intake air heater).
[*3]
11. Remove the air conditioner compressor

assembly according to the following procedure.
1) Loosen air conditioner compressor assembly mounting bolt (13).
2) Loosen air conditioner compressor drive
belt adjustment bolt (14) and remove belt
(15).
[*4]
3)
4)
5)
a
Disconnect wiring harness connector (16).

Remove bracket (17).
Remove air conditioner compressor
[*4]
assembly (18).
Fix air conditioner compressor assembly
(18) to the machine with ropes.
12. Disconnect fuel filter hoses (19) and (20).

a If mud is sticking, lock (L) may become
stiff. Accordingly, clean the connecting
area.
a Press lock (L) from both sides and pull out
hose (20).
a Plug the disconnected hoses to prevent
fuel leakage.
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
13
SEN03950-02

17. Remove 2 clamps (25).
18. Disconnect engine coolant temperature sensor

connector (26).

a While pressing the lock of wiring harness
connector (30), pull the connector in the
19. Disconnect ambient air pressure sensor connector (27) according to the following procedure.
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 connector (28).
23. Disconnect 3 wiring harness connectors (31).

[*5]
a While pressing the lock of the wiring harness connector (31) with flat-head screwdriver [1], pull the connector in the
a Move wiring harness (32) toward the
intake manifold.
50-200
14

SEN03950-02
24. Remove the fuel high-pressure pipe according

1) Disconnect fuel drain hose (33).
[*6]
2) Remove 6 bolts (34).
[*7]
3) Disconnect fuel high-pressure pipe (35).[*8]
4) Remove 6 high-pressure pipes (36). [*9]
a Loosen the sleeve nut on the common rail
side of each high-pressure pipe.
28. Disconnect heater hose (40).

29. Disconnect corrosion resistor hose (41).
30. Remove corrosion resistor and bracket assembly (42).
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

[*11]
assembly (38).
33. Remove cover (45).
27. Remove heat insulation cover (39).
34. Remove the alternator assembly according to

the following procedure.
1)
Disconnect wiring harness terminals CNE02 (46) and CN-E03 (47).
50-200
15
SEN03950-02
2)
3)
Remove fan belt (49).

q
Put the wrench in the concave section
(width across flats: 12.7 mm) of tensioner assembly (48) and turn it in the
unwinding direction to decrease the
tension of fan belt (49).
k Set the wrench securely to the concave section of tensioner assembly (48) before turning it. (The
spring of tensioner assembly (48)
is strong. If the wrench is set
incompletely and turned, it comes
off and that is very dangerous.)
k After removing belt (49), return tensioner assembly (48) slowly and
carefully.
k Take care not to catch your finger
between the pulley and fan belt
(49) during work.
Remove alternator assembly (50).

2)
Remove mounting bolts (54) of exhaust

manifold (53), leaving some of them
installed.
[*13]
3)
Temporarily sling exhaust manifold and

turbocharger assembly (55) and remove
the remaining mounting bolts.
Lift off exhaust manifold and turbocharger
assembly (55).
4 Exhaust
manifold and turbocharger assembly: 40 kg
4)
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]
50-200
16

3)
Position the crankshaft according to the

1] Remove plug (59) under the starting
motor and set tool A4.
Rotate the crankshaft forward (counterclockwise 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 crankshaft 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 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 cylinder is 76 88 before the top dead
center.
a See Testing and adjusting, Adjusting
valve clearance.
a Use tool A4 to rotate the crankshaft.
SEN03950-02
4)
Remove the 12 mounting bolts and rocker

arm (60).
a Loosen locknut (61), and then loosen
adjustment screw (62) by 2 3 turns
so that an excessive force will not be
applied to the push rod when the
rocker arm is installed.
5)
Remove 12 crossheads (63).

a Record the installed positions and the
shapes of holes (a) and (b) of the
crossheads. (When assembling,
install each crosshead to the intake/
exhaust valve from which it was
removed.)
2]
50-200
17

SEN03950-02
6)
Remove retaining nuts (64) and 6 inlet

connectors (65).
a Before removing, clean the inlet connectors carefully so that mud, etc.
sticking around them will not enter
their holes.
a Tool A5 is set for removal of inlet connector (65). (See the special tools
list.)
9)
Using tool A3, remove fuel injector assembly (66).

a Take care that dirt and foreign matter
will not enter the fuel injector assembly mounting area.
37. Remove push rods (69).

38. Remove 7 mounting bolts (70) and rocker
housing (71).
7)
8)
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
Remove 2 mounting bolts (68) of fuel

injector assembly (66).
39. Remove 26 mounting bolts (72) and lift off cylinder head assembly (73).
4
Cylinder head assembly: 75 kg
40. Remove cylinder head gasket (74).
50-200
18

SEN03950-02
Installation
a
1.
2)
The internal parts of the fuel hose adapter may

be damaged when it is removed. Accordingly,
do not reuse the fuel hose but use new one
when assembling as a rule.
When replacing the fuel injector assembly with
new one, be sure to replace the inlet connector
with new one, too.
3)
4)
Cylinder head assembly

1) Using tool A7, measure stem length (a) of
each cylinder head mounting bolt and
check that it is shorter than using limit (b).
(See the special tools list.)
q
Using limit length of bolt (b): 132.1
mm
a If a bolt is longer than the using limit,
replace it.
Set cylinder head gasket (74).

a Check that there is no dirt and foreign
matter on the cylinder head mounting
surface and in the cylinders.
a Check that the holes of the cylinder
head gasket are matched to the holes
of the cylinder head.
Set cylinder head (73) on the cylinder
block.
Tighten 26 mounting bolts (72) 2 3 turns
with the fingers, and then tighten them
according to the following procedure.
2 Threaded part and seat of mounting bolt: Engine oil (EO30)
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
19
SEN03950-02
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)
7)
2.
Fuel injector assembly

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).
2) Apply engine oil (EO30) to O-ring (75) of
fuel injector (66) and the mounting hole on
the cylinder head side.
3) Install holder (77), while setting its concave part to convex part (A) of fuel injector
(66).
8)
9)
4)
5)
50-200
Insert fuel injector (66) in the cylinder

head, directing its fuel inlet hole toward
the air intake manifold.
Tighten 2 mounting bolts (68) of fuel injector (66) by 3 4 turns.
Apply engine oil (EO30) to O-ring (78) of

inlet connector (65) and the mounting hole
on the cylinder head side.
Insert inlet connector (65) securely, while
setting part (B) to the groove on the cylinder head side.
Install rocker housing (71).

3 Rocker housing mounting bolt (70):
24 4 Nm {2.4 0.4 kgm}
Install push rods (69).
20

10) Secure inlet connector (65) by tightening

retaining nut (64) lightly.
15 5 Nm {1.5 0.5 kgm}
11) Tighten 2 mounting bolts (68) of fuel injector (66) alternately.
3 Fuel injector mounting bolt (68):
8.0 0.8 Nm {0.8 0.08 kgm}
12) Tighten retaining nut (64).
50 5 Nm {5.1 0.5 kgm}
13) Install the wiring harnesses to fuel injector

(66) and tighten 2 mounting nuts (67).
3 Wiring harness mounting nut (67):
1.5 0.25 Nm {0.15 0.03 kgm}
a Installed positions of wiring harnesses
Wiring harness
color
Cylinder No.
White
1, 3, 5
Black
2, 4, 6
SEN03950-02
q
Precautions for installing inlet connector

1) When replacing the fuel injector assembly
with new one, be sure to replace inlet connector, 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 filter at rear end (c) of the inlet connector.
3] The O-ring at upper part (d) of the
inlet connector is cracked or deteriorated.
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
21

SEN03950-02
3.
Crosshead and rocker arm assembly

1) Install the crosshead and rocker arm.
a The shapes of holes (a) and (b) of
each crosshead are different. Accordingly, when assembling, install each
crosshead to the intake/exhaust valve
from which it was removed.
2) Check that the ball of adjustment screw
(80) is set in the push rod socket securely
and then tighten mounting bolts (81).
3 Rocker arm mounting bolt (81):
36 5 Nm {3.7 0.5 kgm}
3) Adjust the valve clearance. For details,
see Testing and adjusting, Adjusting
valve clearance.
3 Locknut (79):
24 4 Nm {2.4 0.4 kgm}

[*1]
Wiring harness terminal CN-E07B (7):

4.0 0.6 Nm {0.41 0.06 kgm}
[*2]
3
3
Clamp (8): 7 1 Nm {0.71 0.1 kgm}

Clamp (9):
10.5 0.5 Nm {1.07 0.05 kgm}
[*3]
Engine intake air heater mounting bolt (12a):

24 4 Nm {2.4 0.4 kgm}
[*4]
Adjust the air conditioner compressor belt tension.
For details, see Testing and adjusting, Adjusting
air conditioner compressor belt tension.
[*5]
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-pressure pipe clamps and observe the tightening 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.
50-200
22

1)
2)
3)
4)
Temporarily install fuel high-pressure

pipes (82) (87).
3 Sleeve nut:
0.2 0.8 Nm {0.02 0.08 kgm}
Tighten fuel high-pressure pipes (82)
(87) in the following order.
and (86).
and (86).
5] Tighten the pump side of high-pressure pipe (35) and then tighten the
common rail side.
3 Sleeve nut:
35 3.5 Nm {3.6 0.4 kgm}
Install 6 boots (34) to the fuel high-pressure 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.
Install fuel drain hose (33).
3 Joint bolt:
24 4 Nm {2.4 0.4 kgm}
SEN03950-02
[*12]
3
3
Mounting nut of turbocharger lubricating oil

inlet hose (51): 35 5 Nm {3.5 0.5 kgm}
Mounting bolt of turbocharger lubricating oil
drain tube (52): 24 4 Nm {2.4 0.4 kgm}
[*13]
Tighten the exhaust manifold mounting bolts
3 Exhaust manifold mounting bolts
1st time: Tighten [1] [12] to 24 4 Nm {2.4
0.4 kgm} in order.
2nd time:Tighten [1] [12] to 53 6 Nm {5.4
0.6 kgm} in order.
3rd time: Tighten only [1] [4] to 53 6 Nm
{5.4 0.6 kgm} in order.
[*14]
Blow-by duct mounting bolt:

7 2 Nm {0.7 0.2 kgm}
[*15]
[*10]
Radiator upper hose insertion area:

Gasket sealant
(ThreeBond 1206E or equivalent)
Radiator upper hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}
Cylinder head cover mounting nut (57):

24 4 Nm {2.4 0.4 kgm}
Bleeding air
system.

5
[*11]
Air aftercooler upper hose clamp:

10.5 0.5 Nm {1.07 0.05 kgm}
50-200
23

Removal and installation of engine hood assembly
SEN03950-02

engine hood assembly
4.
Remove partition plate (4).
5.
Disconnect radiator overflow hose (5).
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).
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).
Removal
k
1.
2.
3.

rear frames.
Remove exhaust pipe (1).
50-200
24

9.
Remove stay (1) on the right and left.
SEN03950-02
12. Remove right and left fenders (15).
13. Remove right and left covers (16).
Put wooden block [1] under striker (12) to

prevent the radiator assembly from falling
down.
10. Disconnect water separator wiring harness

connector CN-E42 (13).
11. Remove fuel prefilter and bracket assembly
(14).
a Fix fuel prefilter and bracket assembly
(14) to the machine with ropes.
14. Remove hose (17) between the air cleaner and

turbocharger.
[*1]
15. Disconnect 2 washer hoses (18).

16. Remove wiring clamp (19).
17. Remove rubber cover (20).
50-200
25

SEN03950-02
18. Disconnect rear combination lamp connector
CN-BR1 (21).
21. Lift off engine hood assembly (24).

4
Engine hood assembly: 240 kg
19. Remove 2 front mounting bolts (22) on each of

the right and left sides.
Installation
q

removal.
[*1]
Hose clamp:
10.5 0.5 Nm {1.07 0.05 kgm}
20. Remove 1 rear mounting bolt (23) on each of

50-200
26

Removal and installation of radiator

radiator
SEN03950-02
Removal
k
k
k
1.

rear frames.
7.
Remove air conditioner receiver tank (8) and

[*1]
bracket (9) together.
8.
Disconnect air aftercooler upper hose (10).

6
2.

(1).
3.
9.
4.
Remove 4 bolts (3) and cover (4).
5.

clamps (5).
6.
Remove 4 bolts (6) on the right and left sides

and partition plate (7).
[*2]
Remove the air aftercooler upper hose
since it interferes with the air conditioner
condenser when the latter is removed.
Remove 4 mounting bolts (11) and air conditioner condenser (12).

a Move air conditioner condenser (12) and
the air conditioner receiver tank to the
front of the machine.
50-200
27

SEN03950-02
[*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).
12. Disconnect radiator lower hose (17).
[*4]
13. Fix cooling fan and fan motor assembly (18)

open.
a Check that the cooling fan and fan motor
assembly is locked securely.
16. Remove 2 bolts (19) and cover (20).

a This cover needs to be removed since it
interferes with bolt (19) when the radiator
is removed.
17. Remove radiator (22) from the left side.

[*5]
a When removing the radiator, take care not
to damage the radiator core.
50-200
28

Installation
q

removal.
[*1]
Air conditioner receiver tank mounting Uclamp: 10.8 26.0 Nm {1.1 2.7 kgm}
SEN03950-02
[*5]
a Fit grommet (23) to the mounting hole.
a Check that projection (A) of the radiator is fitted to grommet (23).
a When installing the radiator, set drain hose
(24) in mounting hole (B) securely.
[*2]

10.5 0.5 Nm {1.07 0.05 kgm}
[*3]
Radiator upper hose insertion area:

Gasket sealant
8.8 0.5 Nm {0.9 0.05 kgm}
[*4]
Radiator lower hose insertion area:

Gasket sealant
Radiator lower hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}

5
50-200
29

Removal and installation of air aftercooler
SEN03950-02
Removal and installation of air

aftercooler
4.
Remove upper 2 air aftercooler mounting bolts

(2).
5.
Remove air aftercooler (3) from the left side.

[*2]
a When removing the air aftercooler, take
care not to damage its core.
Removal
k
k
k
1.

rear frames.
6
2.
Remove the radiator. For details,

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.
50-200
30
see

Removal and installation of air aftercooler
SEN03950-02
Installation
q

removal.
[*1]
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).

5
50-200
31

Removal and installation of hydraulic oil cooler assembly
SEN03950-02

hydraulic oil cooler assembly
4.
Disconnect hydraulic oil cooler lower hose (2).

a Plug the disconnected hose to prevent oil
leakage.
5.
Remove 2 upper mounting bolts (3) of the

hydraulic oil cooler.
6.
Remove 2 lower mounting bolts (4) of the

hydraulic oil cooler.
Removal
k
k
k
1.

rear frames.
6
2.
Remove the radiator. For details,

Removal and installation of radiator.
3.
Disconnect hydraulic oil cooler upper hose (1).

a Plug the disconnected hose to prevent oil
leakage.
50-200
32
see

Removal and installation of hydraulic oil cooler assembly
7.
Remove 2 hydraulic oil cooler mounting bolts

(5) on the right side.
SEN03950-02
Installation
q

removal.
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
8.
Remove hydraulic oil cooler assembly (6) from

the right side.
a When removing, take care not to damage
the hydraulic oil cooler core.
Hydraulic oil (For details, see Table of

fuel, coolant and lubricants): Only necessary quantity

5

(For details, see Table of fuel, coolant
and lubricants)
50-200
33

Removal and installation of engine assembly
SEN03950-02

engine assembly
4.
Disconnect fuel prefilter wiring harness clamp

(2) and connector CN-E42 (3).
a The fuel prefilter was removed and fixed in
Removal and installation of engine hood
assembly.
5.
Remove wiring harness clamp (4).
6.
Disconnect alternator wiring harness terminals

CN-E02 (5) and CN-E03 (6).
7.
Remove hose clamp (7).
8.
Disconnect heater return hose (8).
Removal
k
k
k
1.

rear frames.
6
2.

3.
Remove muffler cover (1).

a Remove the muffler cover since it will
interfere with the engine slings (wire
ropes, etc.)
50-200
34

9.
SEN03950-02
15. Remove clamps (15) for the engine wiring harness and air conditioner compressor hose.
10. Disconnect starting motor wiring harness terminal (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
35
SEN03950-02

21. Remove hose clamp (28).

22. Disconnect fuel return hose (29).
20. Remove the air conditioner compressor

1) Loosen air conditioner compressor
assembly mounting bolt (23).
2) Loosen air conditioner compressor drive
belt adjustment bolt (23a) and remove belt
(24).
[*6]
23. Remove 3 fan motor hose clamps (30).
24. Disconnect air aftercooler upper hose (31).

[*2]
3)
4)
5)
50-200
[*3]
Disconnect wiring harness connector (25).

Remove bracket (26).
Remove air conditioner compressor
assembly (27).
36

SEN03950-02
26. Remove mounting bracket (33), then remove

radiator hose mounting bracket (34).
29. Place bar [1] over the frame. Using lever

blocks [3] and [2], sling HST pump assembly
(37) temporarily.
27. Disconnect air aftercooler lower hose (35).

[*4]
28. Disconnect radiator lower hose (36).
[*5]
30. Remove 12 damper cover mounting bolts (38).

[*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
37

SEN03950-02
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
q
33. Remove right and left engine mounting bolts

(41) at the front of the machine.
[*9]
[*1]
34. Remove 4 engine mounting bolts (42) on each

of the right and left side of the front of the
machine to remove bracket (43).
[*10]
a Loosen adjustment bolts (43a) and (43b).
[*2]

removal.
Engine ground cable mounting bolt:

98 123 Nm {10.0 12.5 kgm}

10.5 0.5 Nm {1.07 0.05 kgm}
[*3]
Radiator upper hose:

Gasket sealant
8.8 0.5 Nm {0.9 0.05 kgm}
[*4]
Air aftercooler lower hose clamp:

8.8 0.5 Nm {0.9 0.05 kgm}
[*5]
35. Lift up engine assembly (44) a little and move it
toward the rear of the machine to disconnect it
from the HST pump assembly.
[*11]
36. Lift off engine assembly (44).
a Check that all the electric wiring and
hydraulic piping are disconnected.
a When removing the engine, take care that
it will not interfere with the radiator, air
aftercooler and hydraulic oil cooler.
4
Engine assembly: 700 kg
38
Gasket sealant
Radiator lower hose clamp:
8.8 0.5 Nm {0.9 0.05 kgm}
[*6]
Adjust the air conditioner compressor belt tension.
For details, see Testing and adjusting, Adjusting
air conditioner compressor belt tension.
[*7]
2
3
50-200
Radiator lower hose:
Damper cover mating face:

Gasket sealant (LG-6)
Damper cover mounting bolt:
58.8 73.5 Nm {6.0 7.5 kgm}

SEN03950-02
[*8]
Right and left engine mounting bolts (40) at

rear of machine:
245 308.9 Nm {25.0 31.5 kgm}
[*9]
Right and left engine mounting bolts (41) at

front of machine:
245 308.9 Nm {25.0 31.5 kgm}
[*10]
Right and left engine mount bracket mounting bolts (42) at front of machine:
98 123 Nm {10.0 12.5 kgm}
Adjust clearances (a) and (b) of right and left
engine mount adjustment bolts (43a) and (43b)
at front of machine to the following dimensions
and lock the adjustment bolts.
Clearance (a): 2 mm
Clearance (b): 2 mm
Bleeding air
system.

5
[*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
39

Removal and installation of engine front oil seal assembly
SEN03950-02

engine front oil seal assembly
2.
Remove 4 bolts (2), then remove cover (3).
3.

clamp (4).
4.
Remove 4 bolts (5) on the right and left sides,

then remove partition plate (6).
5.
Remove cover (7).
Symbol
Part No.
Part name
Necessity
Q'ty
New/Remodel
Sketch
Special tools
t 1
790-331-1120 Wrench (angle)
q 1
Removal
k
1.

rear frames.
(1).
50-200
40

6.
Put wrench [1] in the concave section (width

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 concave section of tensioner assembly (8)
before turning it. (The spring of tensioner assembly (8) is strong. If the
wrench [1] is set incompletely and
turned, it comes off and that is very
dangerous.)
k After removing belt (9), return tensioner assembly (8) slowly and carefully.
k Take care not to catch your finger
between the pulley and fan belt (9) during work.
SEN03950-02
8.
Installation
1.
7.
Remove engine front oil seal (12).
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.
Remove 6 mounting bolts (10) and vibration

damper (11).
50-200
41
SEN03950-02

When not using angle tightening tool

5] After steps 1] 3], make marks on the
vibration damper and each bolt with a
paint.
6] Tighten the bolts by 90 5.

q
q
2.
The projection and runout of engine front oil

seal (12) from cover (13) must be in the following range.
Projection (x): Max. 0.38 mm
Facial runout (TIR: Total Indicator Reading) (y):
Max. 0.25 mm
Vibration damper
1) Install vibration damper (8) to the crankshaft while setting the dowel hole of the
former to dowel pin (a) of the latter.
2) Tighten mounting bolts (7) according to
the following procedure.
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 is set for angle tightening. (See the special tools list.)
50-200
42

Removal and installation of engine rear oil seal assembly

engine rear oil seal assembly
Part name
2 795-799-6500 Seal puller
Necessity
Q'ty
New/Remodel
Sketch
Part No.
5.
Install eyebolt [1] to the damper mounting bolt

hole and sling flywheel assembly (4).
6.
Remove the 2 flywheel mounting bolts and

install guide bolts [2].
7.
Remove other 6 mounting bolts (3) and lift off

flywheel assembly (4).
[*2]
Special tools
Symbol
SEN03950-02
Flywheel assembly: 45 kg
t 1
Removal
k
k
k
1.

rear frames.
Loosen the radiator cap to drain the coolant.
6
Radiator: Approx. 26.5 l
2.

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]
8.
Engine rear oil seal

1) Install tool A2 to the crankshaft.
2) Tighten tapping screw [3] of tool A2 into
the seal carrier of engine rear oil seal (5).
3) Rotate the wrench handle clockwise to
remove engine rear oil seal (5).
50-200
43
SEN03950-02

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 a
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.
2.
Insert pilot [4] in crankshaft (6) and push

engine rear oil seal (5) into flywheel housing
(7).
3.
Push in engine rear oil seal (5) further and then

pull out pilot [4].
4.
Using tool A2, install engine rear oil seal (5) to

flywheel housing (7).
a When installing engine rear oil seal (5),
take care not to bend it.
a Projection of engine rear oil seal (5) (x):
Max. 0.38 mm

[*1]
a When installing damper flange (2), direct part
(a) as shown below.
50-200
44
Damper flange mounting bolt (1):

Adhesive (LT-2)
Damper flange mounting bolt (1):
44.1 53.9 Nm {4.5 5.5 kgm}

[*2]
a Tighten the 8 flywheel assembly mounting
bolts in the following order shown below.
a Using a bar, lock the flywheel.
3 Flywheel mounting bolt:
137 7 Nm {13.97 0.71 kgm}
SEN03950-02
q
Measuring facial runout

Facial runout: Max. 0.20 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 end face (c) of the flywheel 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.
After rotating the flywheel by 1 turn, check that
the dial gauge indicates the value at the start
of rotation.
Measuring radial runout

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
system.

5
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
45

Removal and installation of cooling fan and fan motor assembly
SEN03950-02

cooling fan and fan motor
assembly
Part name
8 791-415-2002 Remover
Necessity
Q'ty
New/Remodel
Sketch
Part No.
Remove 4 fuel tank breather hose clamps (3).
4.
Remove clip (5) and disconnect hose (4) from

breather (6).
5.
Remove breather (6).
6.
Remove 3 wiring harness clamps (7).
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.
Special tools
Symbol
3.
q 1
Removal
k
1.
2.

rear frames.
Remove cover (2).
50-200
46

9.
Move the lock portion of stopper link (13) to

hole (A) of bracket (14) to remove it from the
bracket.
10. Remove mounting bolt (16), stopper plate (15)

and nut (17).
[*1]
SEN03950-02
12. Remove 4 mounting bolts (19) and remove fan

[*3]
motor assembly (21) from bracket (20).
Installation
q

removal.
[*1]
Nut (17): 98.0 127.5 Nm {10 13 kgm}

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 {6.0 7.5 kgm}
11. Using tool A8, remove cooling fan assembly

(18).
[*2]
[*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
its key way to key (22).
50-200
47
SEN03950-02

[*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.
5
50-200

48

Removal and installation of fuel tank assembly

tank assembly
SEN03950-02
1.
Disconnect fuel level gauge wiring harness

connector CN-R21 (7).
7.
Remove hose clamp (8).
8.
Disconnect fuel return hose (9) and supply

hose (10).
a Plug the disconnected hoses to prevent
fuel leakage.
9.
Remove power train oil cooler hose clamp (11)

under the front of the radiator.
Removal
k
6.

rear frames.
Drain the fuel from the fuel tank.
6
Fuel tank: Approx. 245 l (When full)
2.

(1).
3.
4.
Remove 4 breather hose clamps (3) of the fuel

tank.
5.
Remove clip (5) and disconnect hose (4) from

breather (6).
10. Remove hydraulic oil cooler hose clamps (12)

and (13) under the front of the hydraulic oil
cooler.
50-200
49

SEN03950-02
11. Support the fuel tank bottom with the transmission jack.
12. Remove fuel tank front mounting bolts (14) on
[*1]
Installation
q

removal.
[*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 the transmission jack.
4
50-200
Fuel tank assembly:

130 kg (excluding fuel)
50

SEN03950-02
50-200
51
SEN03950-02

2009 KOMATSU
All Rights Reserved
50-200
52
SEN03951-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
50

Removal and installation of transfer................................................................................................................ 2
Disassembly and assembly of transfer assembly ........................................................................................... 5
Removal and installation of parking brake assembly .................................................................................... 24
Disassembly and assembly of parking brake assembly ............................................................................... 25
50-310

Removal and installation of transfer
SEN03951-00

transfer
5.
Disconnect motor 1 drain hose (1) and motor 2

drain hose (2).
6.
Disconnect accumulator charge valve drain

hose (3).
7.
Disconnect PA-port hose (4) and PB-port hose

(5) from the brake valve.
8.
Disconnect clutch valve P-port hose (6).
9.
Disconnect transfer cooler hose (7).
Removal
k
k
Stop the machine on a level place and set

the lock bar to the frame.
Press the brake pedal at least 100 times to
release the residual pressure in the brake
accumulator circuit.
Precautions for handling refrigerant
k Collect refrigerant (R134a) beforehand.
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 protective 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.
Wait until the coolant is cooled, and
1.
Recover the refrigerant (R134a).
2.
Loosen the radiator cap to drain the coolant.

6
[*1]
3.
Remove the operator's cab assembly. For

details, see Removal and installation of operator'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

SEN03951-00
13. Sling the transfer assembly temporarily and
remove 2 transfer cushions (13) on right and
left sides.
[*4]
10. Disconnect clamps (8), (9), and (10).
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 transfer 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 disconnected, and then sling the assembly
slowly.
4
Transfer and HST motor assembly:

420 kg
50-310

SEN03951-00
Installation
q

removal.
[*1]
a When installing the hoses of the air conditioner
circuit, take care that dirt, dust, water, etc. will
not enter them.
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.
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 (17).
3
[*4]
[*5]
Threaded part of hose (M24 1.5):

30 35 Nm {3.0 3.5 kgm}
Transfer mount mounting bolt:

610 765 Nm {62.5 78.0 kgm}

again.
5

12 15 Nm {1.2 1.5 kgm}
20 25 Nm {2.0 2.5 kgm}
Transfer cushion mounting bolt:

M10 bolt: 59 74 Nm {6.0 7.5 kgm}
M12 bolt: 98 123 Nm {10.0 12.5 kgm}

5
Hydraulic oil (for details, see Table of

Charging with refrigerant (R134a)

Charge the air conditioner circuit with refrigerant (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 fitted 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

Disassembly and assembly of transfer assembly
SEN03951-00
Disassembly and assembly of

transfer assembly
Disassembly
1
1.
Special tools
Part No.
Part name
790-201-2840 Spacer
t 1
793T-417-1110 Push tool
t 1
t 1
Necessity
Q'ty
New/Remodel
Sketch
Symbol
Transfer assembly
Drain the transfer oil.
790-101-5311 Plate
790-101-5221 Grip
01010-51225
Bolt
793T-417-1120 Push tool
t 1
790-101-5221 Grip
t 1
01010-81225
t 1
Bolt
799-301-1500 Oil leak tester
t 1
799-401-3200 Adapter
t 1
02789-00315
t 1
799-101-5160 Nipple
t 1
790-190-1500 Pump assembly
t 1
Cap
10 790-201-3260 Bolt
(12 x 1.75 mm)
q 2
11 792-735-2420 Collar
t 1
12 792-104-1130
t 1
Collar
q 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
q 1
19 79G-17L-1000 Bar
t 1
20 795-100-1291 Sleeve driver
t 1
21 796-430-1110
t 1
Push tool
22 790-470-1410 Collar
t 1
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
2.
Transfer oil: 7.2 l
Brake accumulator
1) Remove the speed sensor from the transfer case top.
2) Disconnect wiring connectors T06 (1) and
T11 (2).
3)
Disconnect wiring connectors T10 (3) and

T07 (4).
4)
5)
Disconnect clutch port hose (5).

Remove the 6 mounting bolts and bracket
assembly (6).
q 1
50-310

SEN03951-00
3.
HST motor
1) Remove the 4 mounting bolts and lift off
HST motor 1 (7).
2) Remove the 4 mounting bolts and lift off
HST motor 2 (8).
4.
Oil supply pipe and hose

1) Remove oil supply pipe (9).
2) Remove hose (10) from the transfer case
strainer.
5.
3)
6.
Remove the mounting bolts. Using tool

D10, remove parking brake assembly
(15).
a For disassembly and assembly of the
parking brake assembly, see Disassembly and assembly of parking
brake assembly.
Hub
1) Remove snap ring (16).
2) Remove hub (17).
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

7.
SEN03951-00
Belleville springs
1) Turn over the case and remove cage (18)
from the HST motor 1 mounting section.
a Loosen the mounting bolts evenly
and gradually to release the belleville
springs, and then remove the cage.
q
Free height of belleville springs
(7-piece set): 57.4 mm
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}
3)
8.
2)
Remove 7 belleville springs (19).

a Check the directions of the belleville
springs.
a The 1st belleville spring (The one on
the top) has a yellow mark.
a When any belleville spring needs to
be replaced, replace all of the 7
springs as a set.
Piston and spacer

1) Remove piston (20).
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.
50-310

SEN03951-00
9.
Clutch discs, plates, and springs

1) Remove 7 discs (22), 8 plates (23), and 7
wave springs (24).
2)
Remove end plate (25).
10. Coupling
1) Remove the mounting bolts and holder
(26).
2) Remove coupling (27).
11. Cage assembly

1) Remove the mounting bolts. Using tool
D10, remove cage assembly (28).
2)
Remove shims (29).

a Check the thickness and quantity of
the shims.
3)
Remove dust seal (30) and oil seal (31)

from cage (32).
Remove outer race (33).
4)
50-310

12. Spacer
Remove spacer (34).
13. Front case

Remove the mounting bolts. Using tool D10
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.
SEN03951-00
15. Disassembly of HST motor 1 shaft and ring
gear assembly
1) Remove snap ring (37) and sun gear (38).
2)
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).
50-310

SEN03951-00
4)
5)
Remove bearing (42) and spacer (43)

from ring gear (40).
Remove snap ring (44) and bearing (45).
16. Removal of output shaft and gear assembly

1) Remove 2 mounting bolts (47) of cover
(46).
2) Remove output shaft and gear assembly
(49) and cover (46).
17. Disassembly of output shaft and gear

assembly
1) Using tool D12, remove rear bearing (50).
2) Remove gear (51) and spacer (52).
50-310
10
3)
Using tool D13, remove front bearing (53).
18. Removal of carrier assembly

1) Remove 6 bolts (54).
2) Using tool D14, remove carrier assembly
(55).
19. Disassembly of carrier assembly

1) Remove shaft (56) and ball (57) from carrier (58).
a Keep the ball carefully.
2) Remove 2 thrust washers (59), planetary
gear (60), and bearing (61) (at 3 places).

20. Holder
1) Remove mounting bolt (62) and holder
(63).
2)
Remove seal rings (64) and (65) and Oring (66) from holder (63).
SEN03951-00
22. Disassembly of HST motor 2 gear and bearing assembly
1) Using puller D15 and tool D16, remove 2
bearings (69) from HST motor 2 gear (68).
23. Removal of HST motor 1 gear and outer

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).
50-310
11
SEN03951-00
24. Disassembly of HST motor 1 gear and outer
races
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).
25. Bearing
1) Remove 2 plugs (76) from shaft (70).
2)
3)
50-310

26. Rear case

Remove outer race (80) from rear case (79).
27. Clutch housing

1) Using tool D20, remove clutch housing
(81) and 3 pins (82).
2) Remove snap ring (83) from clutch housing (81).
Remove spacer (77).

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).
12

Assembly
a
a
1.
2.
SEN03951-00
3.
Installation of HST motor 2 gear and bearing assembly

Install HST motor 2 gear and bearing assembly
(67).
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
(72).
3 Seal ring: Grease (G2-LI)
5.
Bearing and HST motor 1 gear

1) Using tool D23 and the press, press fit
bearing (78).
Clean the all parts and check them for dirt or

damage. Coat their sliding surfaces with power
line oil (TO10) before installing.
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.
Rear case
Press fit outer race (80) of the output shaft to
rear case (79).
Assembly of HST motor 2 gear and bearing

assembly
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.
50-310
13

SEN03951-00
2)
Install spacer (77).
3)
4)
Install HST motor 1 gear (72).

Using push tool D21 and the press, press
fit bearing (71).
q
Projection of bearing from shaft:
0.92 2.13 mm
2)
7.
6.
Install holder (63) and tighten the mounting 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 diameter (h) on shaft (70)].
2 Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
88.2 107.8 Nm {9 11 kgm}
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).
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

8.
9.
Installation of carrier assembly

1) Install carrier assembly (55), matching it to
the dowel pin of the HST motor 1 gear.
2) Tighten mounting bolts (54).
3 Mounting bolt:
137 196 Nm {14 20 kgm}
SEN03951-00
3)
Install spacer (43) and set bearing (42).

a Take care of the setting direction of
the bearing (flanged).
4)
Using push tool D21 and the press, press

fit bearing (42).
5)
Install snap ring (39).
Assembly of HST motor 1 shaft and ring

gear assembly
1) Install bearing (45) to ring gear (40), and
then install snap ring (44).
2)
Set ring gear (40) to HST motor 1 shaft

(41). Using push tool D21 and the press,
press fit bearing (45).
50-310
15

SEN03951-00
6)
Install sun gear (38) and snap ring (37).
10. Installation of HST motor 1 shaft and ring

gear
Install HST motor 1 shaft and ring gear assembly (36).
2)
3)
Rotate the shaft and set spacer (52).

Install output gear (51).
2 Gear spline: Grease (LM-G)
4)
Using tool D2 and the press, press fit rear

bearing (50).
a After press fitting the bearing, apply
transfer oil to it and rotate it.
11. Assembly of output shaft and gear assembly

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 to it and rotate it.
50-310
16

12. Installation of output shaft and gear assembly

1) Put cover (46) over the gear and install
output shaft and gear assembly (49) to the
rear case.
2) Secure cover (46) with bolts (47).
a Check that cover (46) does not interfere with the inside of the gear.
3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
SEN03951-00
14. Front case
a Use the front case and rear case as an
assembly.
a When installing the cases, match the
match marks on their tops to each other.
1) Apply gasket sealant to the rear case
a Apply the gasket sealant to forcing
screw contact part (a), similarly to the
dimensions for each bolt hole.
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)
3)
Set tool D24 and install front case (35).

3 Mounting bolt:
98 123 Nm {10 12.5 kgm}
Install snap ring (83)
50-310
17

SEN03951-00
3)
Install snap ring (86) on the HST motor 2

side.
4)
Install spacer (34) of the output shaft.
2)
Install 7 discs (22), 7 wave springs (24),

and 8 plates (23).
a Soak the discs in clean transfer oil for
at least 2 minutes before installing
them.
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)
50-310
18
Install the O-ring and piston (20).


17. Belleville springs

1) Set the 1st one (bottom one) of the 7
belleville springs (19) with the convex side
up.
2) Set the 2nd, 4th, and 6th belleville springs
in the opposite direction to the 1st one and
set the 3rd and 5th ones in the same
direction as the 1st one. (There are no
marks on the 1st 6th springs.)
3) Set the 7th belleville spring with the yellow
mark side up.
a When any belleville spring needs to
be replaced, replace all of the 7
springs as a set.
SEN03951-00
18. Cage
1) Install cage (18).
a Tighten the mounting bolts evenly
and gradually.
q
Installed load of belleville springs
(7-piece set): 21,500 N {2,190 kg}
3 Mounting bolt:
245 308 Nm {25 31.5 kgm}
2) After installing cage (18), press fit bearing
(88) with tool D25 and install snap ring
(89).
50-310
19
SEN03951-00
19. Operation test of transfer clutch
Using tool D5, apply oil pressure to transfer
clutch disengagement port (m).
a When the oil pressure is applied, if the
transfer clutch is disengaged, it is operating normally.
q
Clutch disengaging oil pressure:
1.52 MPa {15.5 kg/cm2}
20. Cage assembly

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 (ThreeBond 1855 or equivalent)
50-310
20

21. Adjusting pre-load on output shaft taper

roller bearing
1) Install cage (28) without inserting any
shim.
3 Mounting bolt:
4.80 0.98 Nm {0.5 0.1 kgm}
2) Rotate the output shaft 20 turns and check
the tightening torque of the mounting 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
dispersion to 0.15 mm or less.

4)
5)
6)
7)
8)
Calculate shim thickness (t).

q
Shim thickness (t) = Average of clearance (k) + 0.15 mm to 0.20 mm
Insert selected shim (29) between cage
assembly (28) and the front case.
Tighten the cage mounting bolts.
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
Install holder (26) and the holder mounting

bolt to the output shaft.
Set tool D26 to the holder mounting bolt
and measure the rotating torque of the
output shaft.
a Measure the rotating torque without
installing the front and rear couplings.
q
Rotating torque of output shaft:
4.9 6.7 Nm {0.5 0.7 kgm}
SEN03951-00
22. Coupling
1) Install coupling (27) on the cage side.
2 Spline of coupling: Lubricant containing molybdenum disulfide
(LM-G)
2) Install holder (26) and tighten the mounting bolt.
3 Mounting bolt:
245 308.7 Nm {25 31.5 kgm}
23. Hub
1) Turn over the transfer assembly and install
hub (17).
2) Install snap ring (16).
2 Spline of output shaft: Lubricant
containing molybdenum disulfide (LM-G)
50-310
21
SEN03951-00
24. Parking brake assembly
1) Remove 2 dowel pins (87) from the parking brake assembly.
a The dowel pins may be left on the
transfer case side.
2)
3)
50-310
Install parking brake assembly (15).

a After the all internal teeth of the disc
are meshed with the spline and the
clearance between the parking brake
housing and transfer case is eliminated, 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.
Drive in the dowel pins and tighten the
mounting bolts.
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
22

25. Coupling
Install coupling (14).
2 Spline of coupling: Lubricant containing molybdenum disulfide (LM-G)
26. Oil supply pipe and hose

1) Connect hose (10) to the transfer case
strainer.
2) Install oil supply pipe (9).
27. HST motor

1) Sling and install HST motor 2 (8).
2 Spline of HST motor 2: Lubricant
containing molybdenum disulfide (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}

28. Transfer oil filter

1) Install transfer oil filter bracket assembly
(6) with the 6 mounting bolts.
2) Connect clutch port hose (5).
3)
SEN03951-00
4)
Connect wiring connectors T06 (1) and

T11 (2).
5)
Install the speed sensor to the transfer

case top.
Connect wiring connectors T10 (3) and

T07 (4).
50-310
23

Removal and installation of parking brake assembly
SEN03951-00

7.
Remove the parking brake mounting bolts.

Then, using tool D10, remove parking brake
assembly (10).
[*3]

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
3.
Disconnect transfer lubricating oil pump hose

(9).
Removal
k
6.
Transfer case: 7.2 l
Remove cotter pin (2) and pin (3) of the parking brake cylinder.
[*1]
a The parking brake cylinder is at the front
of the inside of the left rear wheel.
4.
Remove rear drive shaft (7).
5.
Remove coupling (8).
Installation
q
[*2]

removal.
[*1]
a After inserting cotter pin (2) in pin (3), open it to
180.
[*2]
Rear drive shaft mounting bolt:

59 74 Nm {6.0 7.5 kgm}
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
50-310
24
Transfer case: 7.2 l


Disassembly and assembly of parking brake assembly

SEN03951-00
2.
1
Sketch
Part Name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
Plates, discs, and springs

1) Remove 2 clamping bolts (3) and 2 spacers (4).
a Since the spring tension is applied,
loosen the 2 clamping bolts evenly.
t 1
790-101-5201
Push tool kit
790-101-5301
Plate
790-101-5221
Grip
01010-51225
Bolt
793T-417-1120
Push tool
t 1
Grip
t 1
Bolt
t 1
3
D
4 790-101-5221
01010-81225
2)
Disassembly
1.
Remove 5 plates (5), 4 wave springs (6),

and 4 discs (7).
Strainer
1) Remove cover (1).
3.
2)
Cam plate
Remove cam plate (8).
Remove strainer (2).
50-310
25

SEN03951-00
4.
5.
Ball
Remove 6 balls (9).
6.
Pin
Remove pin (12).
7.
Dust seal and oil seal

Remove dust seal (13) and oil seal (14).
8.
Oil seal and bearings

1) Remove oil seal (15).
2) Remove 2 bearings (16) from parking
brake case (17).
Lever
1) Remove the mounting bolt and lever (10).
2)
50-310
Remove lever (11).
26

SEN03951-00
Assembly
a
a
1.
2.

damage. Coat their sliding surfaces with transfer oil (EO10-CD) before installing.
Do not reuse the gasket but remove it completely.
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 outward.
a Check that dirt is not sticking to the ball
groove and inside of the housing.
4.
Lever
Install levers (11) and (10).
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)
50-310
27

SEN03951-00
a
5.
Balls
Install 6 balls (9).
a Check that dirt is not sticking to the balls.
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
When installing the levers (11) and (10),

match their match marks (a) and (b).
3 Mounting bolt:
27 34 Nm {2.8 3.5 kgm}
28
7.
Move cam plate (8) several times so that

balls (9) will be fitted to grooves (c) of cam
plate (8).
Check that the cam plate does not hitch
on the housing.
Plates, disc, and springs

1) Install 4 discs (7), 4 wave springs (6), and
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.

2)
8.
Using tool D27, press plate (5) lightly with

a press and install 2 spacers (4) and 2
clamping bolts (3).
a Take care not to press plate (5) too
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 Clamping bolt: Adhesive (LT-2)
3 Clamping bolt:
19.6 27.4 Nm {2.0 2.8 kgm}
SEN03951-00
2)
Install the O-ring and cover (1).

3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
Strainer
1) Install strainer (2).
50-310
29
SEN03951-00

2008 KOMATSU
All Rights Reserved
50-310
30
SEN03952-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
50

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
50-320

Removal and installation of front axle assembly
SEN03952-00
Removal and installation of front

axle assembly
3.
Remove work equipment valve upper cover

(2).
4.
Disconnect wiring connector F14 (3) and

clamp (10).
5.
Disconnect brake hose (4).
Removal
k
1.
2.
Stop the machine on a level ground and

install the lock bar to the frame to lock the
front and rear frames.
Release the remaining pressure in the
brake accumulator circuit. For details, see
Testing and adjusting, Releasing remaining pressure in hydraulic circuit.
Set the support stand to the frame securely.
Raise the front part of the chassis with the
work equipment and set support stand [1]
under the frame at the rear of the front wheel to
float the front part of the chassis.
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

Removal and installation of front axle assembly
6.
Disconnect front drive shaft (5).
SEN03952-00
[*2]
Installation
q

removal.
[*1]
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
bolts on both sides and front axle assembly
(6).
[*3]
4
[*3]
Front axle mounting bolt:

1325 1470 Nm {135 150 kgm}
Front axle assembly: 730 kg

q
Bleeding air
Bleed air from the brake system. For details,
see Testing and adjusting, Bleeding air from
brake system.
50-320

Removal and installation of rear axle assembly
SEN03952-00
Removal and installation of rear

axle assembly
4.
Lift off rear wheel (1).

[*1]
a Lift off the rear wheel on the other side
similarly.
4 Rear wheel (1 side): 340 kg
5.
Disconnect brake hose (2) from the axle.
6.
Disconnect 2 grease tubes (3).
7.
Change the outlet direction of oil pan drain

hose (4).
Removal
k
k
k
1.

Lower the work equipment to the ground
and stop the engine.
Release the remaining pressure in the
brake accumulator circuit. For details, see
Testing and adjusting, Bleeding air from
brake accumulator circuit.
Set the support stand to the frame securely.
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.
2.
Lower the work equipment to the ground horizontally 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.
50-320

8.
Remove rear drive shaft (5).

[*2]
a Remove coupling (6) to avoid damaging
dust seal (8) in step 11.
9.
Remove bracket (8) of relay assembly (7). [*3]
SEN03952-00
11. Pull out the rear axle assembly backward to
disconnect it from the rear frame assembly.
a When disconnecting the rear axle assembly, take care not to damage dust seal (8)
of rear frame (12).
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, support it on jack [3], and remove the mounting
bolts (11) of support (10).
[*4]
50-320
SEN03952-00

Installation
q

removal.
[*1]
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.
a When installing the drive shaft, check that the
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]
Support mounting bolt:

1325 1470 Nm {135 150 kgm}
Bleeding air
Bleed air from the brake system. For details,
see Testing and adjusting, Bleeding air from
brake system.
50-320

Disassembly and assembly of axle housing assembly

axle housing assembly
SEN03952-00
Symbol
3
4
5
H
Part No.
Part name
Necessity
Q'ty
New/Remodel
Sketch
Special tools
793T-623-1170 Push tool
t 1
793T-422-1440 Push tool
t 1
t 1
t 1
01016-50860
t 6
Bolt
793T-659-1110 Push tool
t 1
790-201-2750
t 1
Spacer
793T-422-1430 Holder
t 1
790-101-5201
Push tool kit
t 1
790-101-5271
Plate
790-101-5221
Grip
01010-51225
Bolt
790-101-3101
Bearing puller
q 1
790-101-3501
Gear puller
q 1
2)
Sling rear support (30) temporarily and

remove cover (31).
Remove thrust plate (32) and rear support

(30).
Remove brake tube and hose assembly
(33).
Q
Q
791T-465-1130 Push tool
t 1
790-201-2670
Plate
t 1
799-501-1120
Pin
t 1
10 790-445-5980
Guide bar
t 1
3)
11 Commercially
available
Dial gauge
q 1
4)
8
9
79A-264-0021
12 or commerPush-pull scale
cially available
q 1
Disassembly
a
The following photos and illustrations show the

rear axle housing as an example.
1.
Draining oil
6
2.
Axle (Each of front and rear axles): 24 l
Axle assembly
1) Set the axle assembly on block [1] and
jack [30].
a Set jack [30] so that the axle assembly will not lean when the housing
assembly on one side is removed.
50-320

SEN03952-00
3.

1) Sling axle housing assembly (1) temporarily and remove the housing mounting
bolts and axle housing assembly (1).
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)
k
50-320
4.
Brakes
a Remove both brakes according to the following procedure.
1) Remove 2 inside hexagon bolts (34).
2)
Remove 2 plates (35), 2 discs (36), and 2

wave springs (37).
3)
4)
Remove end plate (38).

Remove sun gear shaft (39).
Set axle housing assembly (1) with the

brake side up.
When working, take extreme care that
the axle housing assembly will not fall
down.

5.
Planetary carrier assembly

1) Remove axle shaft mounting bolt (2).
2)
SEN03952-00
6.
Axle shaft
1) Sling axle housing assembly (5) about 20
mm.
Remove planetary carrier assembly (3).

2)
3)
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.
Remove shim (4).

a Record the thickness and quantity of
the shims.
50-320

SEN03952-00
7.
Axle shaft bearing

a Do not heat the bearing to remove it or cut
it with gas.
1) When removing bearing (7) from axle
shaft (6), evenly push in part (a) around
the oil seal and sleeve (8) with a screwdriver toward the flange.
2) Make clearance (b) at the contact part of
bearing (7) and sleeve (8a) to hitch the
claws of the puller.
3) Install tool H6 securely to clearance (b).
4) Tighten the bolts of tool H6 to remove
bearing (7).
8.
Axle housing
1) Remove 3 pins (10) from axle housing
(11). (You can pull them out with the
hand.)
2) Using tool H7, pull up ring gear (9) evenly
to remove it from axle housing (11).
a Install tool H8 to the bolt end of tool
H7 to adjust the height.
a Take care that the claws of the puller
will not come off the ring gear.
3)
50-320
10
Remove outer races (12) and (13) from

axle housing (11).

9.
Planetary carrier
1) Using tool H9, drive in roll pin (15) of planetary carrier (14) until it is in the range of
shaft (16).
a Take care not to drive in the roll pin
too deep.
SEN03952-00
3)
Pull roll pin (15) out of removed shaft (16).
4)
Remove pinion gear (17) and 2 bearings

(18) from planetary carrier (14).
Similarly, remove the 2nd and 3rd pinion
gears (17) and 2 sets of shaft (16), roll pin
(15), and bearing (18) from planetary carrier (14).
Remove spacer (19) from planetary carrier
(14).
5)
6)
2)
Using tool H10, push out shaft (16) with a

press.
50-320
11

SEN03952-00
10. Rear axle support (Rear axle only)
1) Remove thrust washer (50) and retainer
(51) from rear axle support (30).
2)
50-320
Remove bushing (52) from rear axle support (30) and remove packing (53) from
the retainer side.
12
Assembly
1.
Axle housing and axle shaft

1) Press fit bearing outer races (12) and (13)
to axle housing (11).
2)
Using tool H1, press fit seal (8) and bearing (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 clearance will be even.

2.
Axle shaft bearing

1) Erect axle shaft (6) on the block and fix it
securely.
k Perform the work carefully so that the
axle shaft will not fall.
2) Sling axle housing (11) vertically, and then
lower it slowly.
a Insert the axle housing by utilizing its
weight.
2 Fitting part of oil seal and bearing:
Axle oil (AXO80)
a After installing the housing, leave tool
H2 installed until step 4).
3) Using tool H3, press fit bearing (20) to
axle shaft (6).
a Press fit the bearing, turning the axle
housing with the hand.
2 Outside of bearing:
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.)
SEN03952-00
3.
Selecting shims
1) After bearings (7) and (20) are fitted well,
measure the turning force of hole (d) of
axle housing (11).
a Carry out this work before installing
the planetary carrier.
q
Turning force (Not static friction, but
dynamic friction)
(Common to front and rear)
(Including seal resistance)
25.5 49 N {2.6 5.0 kg}
a
a
If the turning force is below the standard value, press fit the bearings
again and perform the work in step 1).
If the turning force exceeds the standard value, adjust it according to following steps 2) 4).
9JS01378
9JF00886
50-320
13

SEN03952-00
2)
3)
4)
Hold 2 parts of axle shaft and housing

assembly (5) and sling it by 20 30 mm,
as you installed the axle housing.
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).
Adjust the turning force to the standard
value according to step 1).
9JS01379
4.
Planetary carrier
1)
5)
6)
7)
50-320
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)
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.
Using a depth micrometer, measure distance (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
After determining the shim thickness,
remove planetary carrier (14).
14

2)
3)
SEN03952-00
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
ring gear.
6.
Planetary carrier assembly

1) Install shim (4) selected in steps 3 to the
end of the axle shaft.
Install spacer (19) in planetary carrier (14).

a Insert the spacer from (g) side of
planetary carrier (14) before installing
2nd gear (17).
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 differential side of gear (17) lightly to push
back the bearing and check that the
gear rotates smoothly.
50-320
15
SEN03952-00
2)
Sling and install planetary carrier assembly (3).

k When installing the planetary carrier, take care not to catch your fingers in the gear.
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}
a Clean the shaft end and planetary
c ar rier s pline thoroughly before
installing.
50-320
16

4)
Install dial gauge [9] to axle housing (11)

and measure the end play of the planetary
carrier.
q
End play of planetary carrier:
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 procedure referring to 3. Selecting
shims.
5)
Rotate axle housing (11) 10 or more turns

to fit it. Then, using push-pull gauge [10],
measure the starting effort at the mounting
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.

7.
SEN03952-00
Brake
1) Install end plate (38).
2) Install sun gear shaft (39).
4)
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
notches of the springs, A, and brake
port must be set as shown in the following figure.
a Match the concave lug of lower plate
(40) to wear gauge (41).
a Match the convex lug of upper plate
(35) to wear gauge (41).
a Wear gauge (41) is seen before
upper plate (35) is set but not seen
after upper plate (35) is set.
8.
Install 2 inside hexagon bolts (34).

1) Degrease and clean the mating faces of
the axle housing and differential housing
and dry them in air.
2) Apply a string of gasket sealant 2 3 mm
in diameter to part (P) of differential housing (1).
a Take care that gasket sealant will not
project into hollow parts (r) of the
housing.
2 Mating faces of housings:
Gasket sealant (LOCTITE 515 or
equivalent)
50-320
17

SEN03952-00
3)
2)
Sling axle housing assembly (1) horizontally and install it carefully, matching it to
the spline grooves of the sun gear shaft.
3)
4)
Tighten the axle housing mounting bolts in

the diagonal order.
3 Mounting bolt:
245 309 Nm {25.0 31.5 kgm}
4)
9.
Sling and install rear axle support (30) and

install thrust plate (32).
2 Periphery of pivot mounting part:
Grease (G2-LI)
3 Mounting bolt:
490 608 Nm {50 62 kgm}
Install brake tube and hose assembly (33).
Rear axle support

1) Fit packing (53) to retainer (51) and install
bushing (52), thrust washer (50), and
retainer (51) to rear axle support (30).
a Clean and dry the inside of the support 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).
2 Inside of packing:
Grease (G2-LI) (Apply thinly)
Install cover (31).

3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
Refilling with oil (Axle housing)

Tighten the drain plug and add oil through the
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
50-320
18
Axle oil (AXO80) (Each of front and

rear): 24 l

Disassembly and assembly of differential assembly
SEN03952-00

differential assembly
2.
Removal of long cage assembly (For only

front differential)
1) Set the axle assembly on block [1] and
jack [30].
a Remove the coupling protector only
when it needs to be removed.
3) Remove long cage assembly (24).
3.
Disassembly of long cage assembly (For

only front differential)
Symbol
Part No.
Part name
Necessity
Q'ty
New/Remodel
Sketch
Special tools
13 799-301-1500
14 797-101-1211
Oil leak tester

Wrench
t 1
t 1
15 793-615-1100
16 790-201-2840
Wrench
Push tool
t 1
t 1
17 797T-423-1320 Push tool

18 792T-413-1130 Push tool
t 1
t 1
19 793-520-2202 Installer
20 790-190-1500 Pump assembly
q 3
t 1
21 799-101-5210 Nipple
22 793T-422-1611 Plate
t 1
t 1
23 791T-465-1210 Push tool

24 790-201-3280 Bolt (14 x 2.0 mm)
t 1
q 4
H 25 790-201-3260
26 791-615-2130
Q
Q
Q
Q
Bolt (12 x 1.75 mm) q 2

Sleeve
t 1
27 Commercially Puller
available
28 79G-05V-1400 Bar
q 1
29 Commercially
available
Commercially
30 available
Depth gauge
q 1
Torque wrench
q 1
t 1
31 791T-630-2230 Push tool

Commercially
32 available
Dial gauge
t 1
33 790-201-2830
34 791-126-0211
t 1
t 1
Spacer
Adapter
q 1
Disassembly of front differential

1.
Draining oil
6
a
q
2)
Using tool H23, push shaft (26) with a

press to remove it from long cage (27).
Axle (Each of front and rear axles): 24 l
When disassembling the rear differential

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.
Perform the procedure in 6. Differential
assembly and after.
Perform following steps 2 5 when disassembling the front differential.
50-320
19

SEN03952-00
3)
4.
Remove snap ring (28) and ring (29), and

then remove bearing (30) from long cage
(27).
Removal of front cage assembly (Front differential)

1) Using tool H14, loosen nut (31) before
removing the cage assembly.
2)
3)
4)
5)
50-320
Remove cover (10).

Remove the axle oil temperature sensor
(which is hidden by cover (10)) and wiring
harness (11) together.
Remove brake tube assembly (12).
Remove the mounting bolts of front cage
assembly (32).
20
6)
Using tool H24, remove front cage assembly (32).

the shims.
5.
Axle housing
a Referring to Disassembly and assembly of
axle housing assembly, 3. Axle housing
assembly, 1), remove the right and left
axle housings.
6.
1) Place and stabilize differential assembly
on block [1].
a The photo shows the rear differential.
a Remove the right and left rear differentials according to the same procedure.
2) Remove 2 slack adjusters (22).
3) Remove 2 bleeder screws (19).
4) Remove piston (20).
a Perform this step for only rear differential.
6) Remove the mounting bolts of top cover
(21).

7.
7)
Using tool H25, remove top cover (21).
8)
Remove seal (87) from piston (20).
SEN03952-00
2)
Using tool H26, push out pinion gear

assembly (81) with a press.
3)
Using bearing puller [31] and tool H26,

push bearing (35) out of pinion gear (36)
with a press.
4)
Remove bearing (37), outer races (38)

and (39) from cage (40).
Disassembly of front cage assembly (For

front differential)
1) Remove nut (31) and holder (33).
50-320
21
SEN03952-00
8.
9.
Removal of rear cage assembly (For rear

differential)
Remove the mounting bolts. Using tool H24,
remove rear cage assembly (42).
a Record the thickness and quantity of the
shims.

10. Bearing carriers

1) Sling differential carrier assembly (43)
temporarily.
2)
Remove the mounting bolts and both

bearing carriers (44), using tool H25.
a Make marks on both bearing carriers
so that they will not be mistaken.
the shims.
3)
Remove seal (84) and ring (85) from each

bearing carrier (44).
a Keep the seal, ring, and shim as a
set.
Disassembly of rear cage assembly (For

rear differential)
2)
50-320
For the further disassembly procedure for

the rear cage assembly, see steps 2) 4)
in 7. Disassembly of front cage assembly
shown above.
22

4)
Using tools H6 and H27, remove bearing

(86) from each bearing carrier (44).
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
assembly by hitting it against the differential case.
2) Remove the 4 mounting bolts and gear
cover (42).
SEN03952-00
12. Disassembly of standard differential carrier
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.
2)
Remove 20 mounting bolts (46) and bevel

gear (47).
3)
Reverse the case and disconnect cases

(48) and (49).
a Before disconnecting, make match
marks on the cases.
50-320
23
SEN03952-00
4)
5)
Remove washer (51) from case (48).

Remove side gear (52) from case (49).
6)
Remove pinion gear assembly (53) from

case (49).
7)
50-320
Remove 4 spherical washers (54) and 4

pinion gears (55) from spider shaft (56).
24

8)
Remove side gear (57) from case (49).
9)
Remove washer (58) from case (49).
10) Using a puller, remove outer race (61)

from case (49).
a Remove the outer race of case (48)
on the opposite side similarly.

13. Disassembly of limited slip differential

assembly (If equipped)
a If the machine is equipped with the limited
slip differential assembly, disassemble it
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.
2)
3)
SEN03952-00
4)
Remove washer (66).
5)
Remove 2 plates (67) and 2 discs (68).
6)
Remove pressure ring (69).

a Insert a finger in the hole on the side
of the case to raise the pressure ring.
Remove 20 mounting bolts (46) and bevel

gear (47).
Place the case upside down and remove

cover (63).
a Before disconnecting the cover, make
match marks on it and case.
50-320
25
SEN03952-00

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

shaft (73).
12) Remove 2 plates (76) and 2 discs (77).
50-320
26

SEN03952-00
13) Remove washer (78).
Removed parts
Assembly
a

damage. Coat their sliding surfaces with axle
oil (AXO80) before installing.
1.
Assembly of limited slip differential assembly (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).
50-320
27
SEN03952-00
4)
5)
6)
50-320
Install 2 plates (76), 2 discs (77), 2 plates

(76), and 2 discs (77) in order from the
bottom.
2 Before installing the discs and plates,
soak them in axle oil (AXO80).

7)
Install 4 pinion gears (72) to spider shaft

(73).
8)
Install pinion gear assembly (71).
9)
Install side gear (70).
Install pressure ring (75).
Install side gear (74).
28

SEN03952-00
10) Install pressure ring (69).
11) Install 2 discs (68), 2 plates (67), 2 discs

(68), and 2 plates (67) in order from the
bottom.
2 Before installing the discs and plates,
soak them in axle oil (AXO80).
12) Selection of thickness of plate

i) Using tool H29, measure distance (d)
between the end of case (64) and
plate (67).
a Distance (dd) [(d) 4.8 mm] is
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
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
washer so that it will stick to the
cover.
a When installing the cover, match the
ma tch mark s made when it was
removed.
50-320
29
SEN03952-00
14) Adjust the clearance of the side gear in
the axial direction.
i) Measure clearance (e) between the
side gear and washer through the
shaft holes on both sides of the limited slip differential.
q
Clearance (e):
0.15 0.35 mm (on each side)
a If the clearance is out of the standard range, replace the washer
with new one.
a There are washers 2.0 mm and
2.1 mm thick.

15) Install cover (63) to case (64).

2 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
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}
50-320
30
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.

17) Measure the no-load operation torque.

i) Install sun gear shafts (14) to both
sides of limited slip differential assembly (83).
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 measure 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, disassemble the limited slip differential again and perform 12)
Selection of thickness of plate
and 14) Adjustment of side gear
in axial direction.
2.
Assembly of standard differential carrier

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.
SEN03952-00
3)
Install washer (58) to case (49) on the

bevel gear side.
a Install the washer with the dimpled
side up (toward the side gear).
4)
Install side gear (57) to case (49).
5)
Install 4 pinion gears (55) and 4 spherical

washers (54) to spider shaft (56).
50-320
31

SEN03952-00
6)
Install pinion gear assembly (53) to case

(49).
7)
8)
Install side gear (52) to case (49).

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.
10) 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}
3.
9)
50-320
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.
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}
32

SEN03952-00
a
4)
4.
Rotate the bearing several turns to

spread the axle oil to every part of the
bearing.
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 standard 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 adjustment to 0.3 1.25 mm on each side.
Bearing carrier
1) Using tool H31 and a press, press fit bearing (86) to bearing carrier (44).
2) Install ring (85) and seal (84) to bearing
carrier (44).
5.
3)
Assembly of front cage assembly (For front

differential)
1) Install outer races (39) and (38) to cage
(40).
Apply axle oil to the bearing. Using H25,

install shims (87) and bearing carriers (44)
on both sides.
a Install the shims of the thickness and
quantity checked when disassembled to each bearing carrier.
a Turning the bevel gear, tighten the
mounting bolts.
2 Bearing: Axle oil (AXO80)
3 Mounting bolt:
98 122.5 Nm {10.0 12.5 kgm}
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33

SEN03952-00
2)
Using tool H16 and a press, install bearing

(35) to pinion gear (36).
6.
3)
4)
5)
6)
7)
50-320
Erect pinion gear assembly (81) and

install cage assembly (88).
Install bearing (37) to pinion gear assembly (81).
a Install the bearing by shrink fit at temperature below 100C or by using tool
H17 and a press.
Assembly of rear cage assembly (For rear

differential)
1) Referring to 5. Assembly of front cage
assembly, steps 1) 4), assemble the
rear cage assembly.
2) Apply axle oil to the bearing and rotate the
cage several turns to spread the axle oil to
every part of the bearing.
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}
Install holder (33) and nut (31).

a Replace nut (31) with new one.
Using tool H14 (See 4. Removal of front
cage assembly), tighten nut (31) to the
specified torque.
a Secure assembly by gripping the outside of the pinion gear in a vise.
3 Mounting nut:
441 539 Nm {45 55 kgm}
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 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 starting torque again.
34

4)
5)
6)
7.
SEN03952-00
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 starting torque again.
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 assembly, and then install shim (90), O-ring, and rear
cage assembly (42).
a For the adjustment of the shims and tightening torque, see 7. Installation of front
cage assembly.
9.
Adjusting backlash
Measure the backlash of the bevel gear with
tool H32.
q
Standard backlash: 0.20 0.33 mm
a Measure the backlash at 3 places on the
periphery of the bevel gear and check that
the dispersion of the measured values is
0.1 mm or less.
Install coupling (41).

3 Mounting bolt:
245 309 Nm {25.0 31.5 kgm}
Installation of front cage assembly (For

front differential)
Install tool H24 to the differential case assembly, and then install shim (89), O-ring, and front
cage assembly (32).
a Install the shims of the thickness and
quantity checked when disassembled to
each bearing carrier.
a Install the shims with the thinnest one on
the cage side.
q
Adjustment allowance of shims:
0.74 1.4 mm
q
0.05 mm, 0.2 mm, 0.3 mm, 0.6 mm
3 Mounting bolt:
157 196 Nm {16 20 kgm}
50-320
35
SEN03952-00
1)
If the measured backlash is out of the

standard range, adjust it by moving a part
of the shims on either side to the opposite
side.
a Do not change the total thickness of
the shims on both sides.
a If the backlash is insufficient, move a
part of shims (g) to the shims (f).
(Move the bevel gear in direction (A),
or to the right in the figure.)
a If the backlash is too large, move a
part of shims (f) to the shims (g).
(Move the bevel gear in direction (B),
or to the left in the figure.)

10. Testing tooth contact

Apply red lead thinly to the surfaces of the
bevel gear teeth and turn the bevel gear in the
forward and reverse directions, then check the
tooth contact pattern on the bevel gear.
a The center of the tooth contact must be as
follows.
q
Middle of tooth height
q
Point on tooth at which distance of (x)
from small end (C) is 24 4 mm
a Width (y) of the tooth contact must be 31
3 mm.
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 follows. 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 direction (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.
the shims on both sides of the bearing carrier.
50-320
36

3)
SEN03952-00
4)
If the bevel gear is too close to the bevel

pinion, the tooth contact pattern is as follows. In this case, adjust the tooth contact
q
Decrease the shims of the cage
move the cage assembly in the direction (C).
q
the direction of (D) far from the bevel
pinion.
5)
If the bevel gear is too far from the bevel

pinion, the tooth contact pattern is as follows. In this case, adjust the tooth contact
q
Increase the shims of the cage
move the cage assembly in the direction (E).
q
the direction of (F) close to the bevel
pinion.
If the bevel pinion is too close to the bevel

gear, the tooth contact pattern is as follows. In this case, adjust the tooth contact
q
Increase the shims of the cage
move the cage assembly in the direction (E).
q
the direction of (F) close to the bevel
pinion.
50-320
37
SEN03952-00

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.
2)
Using tool H19, press fit piston (20)

evenly.
a Press fit the piston until it touches the
housing.
a Do not hit the piston with a plastic
hammer, etc. to press fit it. (If it is
press fitted so, it and its O-ring will be
damaged.)
3)
4)
Install bleeder screw (19).

Install tool H22.
a You may install tool H22 when checking 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}
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.
5)
50-320
38
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
H19) set.
k If the brake oil leakage test is performed without setting installer
[24], the piston will jump out, and
that is dangerous.
2) Install tool H22, nipple H21, and pump
H20 to the brake port and bleed all air
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)
4)
5)
Perform the low-pressure oil leakage test.

a Operate tool H20 to raise the pressure to 98 kPa {1 kg/cm2}.
a Leave the system at 98 kPa {1 kg/
cm2} for 5 minutes and check that the
pressure does not lower at all.
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 pressure is measured, the pressure fluctuates. Accordingly, do not move the
hose.
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 pressure is measured, the pressure fluctuates. Accordingly, do not move the
hose.
Remove pump H20, nipple H21, tool H22,
and installer [24] (equivalent to tool H19),
and then perform the test on the opposite
side.
SEN03952-00
14. Top cover
1) Remove bleeder screw (19) temporarily
and install top cover (21).
2 Mating face of cover: Adhesive
(LOCTITE 515 or equivalent)
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
2) Install slack adjusters (22) to the right and
left.
a Take care that the O-ring will not
come off.
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
3) Install bleeder screw (19).
15. Axle housing

1) Referring to Disassembly and assembly of
axle housing, 8. Axle housing assembly,
install the right and left housings.
2) For the rear differential, perform step 10.
in the Disassembly and assembly of axle
housing to install the rear axle support and
the brake tube and hose assembly.
a Perform steps 16 18 below for only
the front differential.
50-320
39
SEN03952-00
16. Axle oil temperature sensor (For only front
differential)
1) Install axle oil temperature sensor and wiring harness assembly (11).
a Install the axle oil temperature sensor
to the back side of cover (10).
2 Threads: Gasket sealant (LG-5)
3 Axle oil temperature sensor:
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}
50-320
40

17. Disassembly of long cage assembly (For

only front differential)
1) Using tool H33, press fit bearing (30) to
shaft (26) with a press.
a Direct shield side (G) of the bearing
down.
2) Using tool H34, press fit shaft and bearing
assembly (91) to long cage (27).
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.

SEN03952-00
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) Install coupling (23).
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}
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
50-320
41
SEN03952-00

2008 KOMATSU
All Rights Reserved
50-320
42
SEN03953-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
50

Removal and installation of center hinge pin .................................................................................................. 2
Removal and installation of counterweight ................................................................................................... 12
50-400

Removal and installation of center hinge pin
SEN03953-00
Removal and installation of center

1
hinge pin
Symbol
Part No.
Part Name
Necessity
Q'ty
New/Remodel
Sketch
Special tools
t 1
1
790-101-5201
790-101-5281
Push tool kit

Plate
790-101-5221
01010-51225
Grip
Bolt
2
3
793-840-1410
793-840-1420
Push tool
Push tool
t 1
t 1
793-415-1180
Push tool
t 1
1
Y
1
1
Removal
k
1.
2.

rear frames.
Set supports to the frame securely.
3.
Remove operator's cab and floor frame

assembly (1). For details, see Removal and
installation of operator's cab and floor frame
assembly.
4.
Remove upper cover (2) of the work equipment valve.
5.
Disconnect all wiring harness clamps (3)

between the front frame and rear frame from
the rear frame.
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.
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

6.
Disconnect brake hose (4).
SEN03953-00
[*1]
9.
Remove brake hose clamp (8).
10. Disconnect PPC hoses (9) (12) from the work

[*3]
equipment control valve.
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 equipment valve seen from the rear lower direction.
50-400

SEN03953-00
12. Remove pins (11) and hoses (12) and (13)
from the bottom side of both steering cylinders
to disconnect these cylinders.
[*4]
shims.
13. Remove the lower hinge pin.

1) Remove lock bolt (14a).
2) Remove lower hinge pin (14b).
2)
Remove the mounting bolt, cover (15) and

shim (17).
the shims.
3)
Adjust the height of the front frame and

rear frame with the hydraulic jack so that
you can pull out the pin easily, and then
remove upper hinge pin (16).
[*7]
Remove upper spacer (18).
[*5]
4)
14. Remove the upper hinge pin.

[*6]
1) Remove mounting bolt (14c).
the shims.
15. Disconnect the front frame and rear frame. [*8]

1) Set hand lift truck [4] under bucket (19).
AJF00736
50-400

2)
Using a bar, etc., raise front frame assembly (20) by 2 3 mm to move lower spacer
(21) of the upper hinge from rear frame
assembly (22).
a You may raise the front frame assembly by 2 3 mm with a large-sized
crane, if available.
SEN03953-00
2)
3)
Remove retainer (24) and shims (25).

the shims.
Remove dust seal (26) from retainer (24).
AJF00740
9JF00909
4)
3)
Remove bearing (27a) and spacer (27b)

with push tool Y1.
Turn the tires to move front frame assembly (20) forward.
AJF00737
16. Disassemble the lower hinge of the front

frame.
[*9]
1) Remove dust seal (23).
17. Disassemble the upper hinge of the front

frame.
[*10]
1) Remove lower spacer (28).
2) Remove dust seal (29).
3) Remove retainer (30) and shim (31).
the shims.
4) Remove dust seal (32) from retainer (30).
AJF00739
50-400

SEN03953-00
5)
Remove bearing (33a) and spacer (33b)

with push tool Y2.
Installation
removal.
[*1]
a Bleed air from the brake. For details, see Testing and adjusting, Bleeding air from brake circuit.
[*2]
18. Remove 2 bushings (34) from the lower hinge

of the rear frame.
[*11]
AJF00743
Front drive shaft mounting bolt:

59 74 Nm {6.0 7.5 kgm}
When installing the drive shaft, check that the
key way of the spider cap is fitted in the key
mounting bolts.
[*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
(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.
q
0.5 mm, 1 mm
2 Inside of bushing on cylinder side and
dust seal:
Lubricant containing molybdenum
disulfide (LM-P)
50-400

[*5] [*6] [*7] [*8]

a Install the upper hinge pin and lower hinge pin
1.
Set hand lift truck [4] under the bucket and turn
the tires to move the front frame assembly (20)
toward the rear frame.
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).
a You may raise the front frame assembly
by 2 3 mm with a large-sized crane, if
available.
9JF00909
3.
SEN03953-00
4.
Insert upper hinge pin (16) and lower hinge pin

(14b) to the end.
5.
Install upper spacer (18).

a Install the spacer with the chamfered part
on the bearing side.
2 Upper spacer:
disulfide (LM-P)
6.
Tighten cover (15) of upper hinge pin (16) with

3 bolts of the centre.
a Do not insert the shim for the upper hinge
pin,
2 Mounting bolt:
Adhensive: (Loctite #2701)
3 Mounting bolt:
186 226 Nm {19 23 kgm}
7.
Measure clearance between the bottom of

cover (15) and rear frame top with a clearance
gauge, and then select shims so that the maximum clearance will be less than 0.2 mm when
shim (17) are inserted.
q
Standard shim thickness: 1 mm
q
0.1 mm, 0.5 mm
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.
50-400

SEN03953-00
8.
Insert selected shim (17) between cover (15)

and rear frame and tighten the 6 mounting
bolts.
2 Mounting bolt:
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
9.
Install lock bolt (14a) of lower hinge pin (14b).
[*9] [*10] [*11]

a Assemble the upper hinge and lower hinge
1. Install 2 bushings (34) to the lower hinge of the
rear frame.
AJF00743
2.
A clearance of 1 mm should be made at

(b) between bushing (35) and lower hinge
pin (14b).
9JF00917
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)
and spacer (33b) is adjusted properly,
do not change their combination.
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 a clearance will
not be made between the bearing and
frame.
2 Bearing: Grease (G2-LI)
10. Install mounting bolt (14c) of upper hinge pin

(16).
50-400

2)
3)
Press fit dust seal (29) to the front frame.

a Press fit the dust seal with the lip out.
2 Lip of dust seal: Grease (G2-LI)
Install lower spacer (28).
a Install the spacer with the chamfered
part on the bearing side.
2 Lower spacer:
Lubricant containing molybdenum disulfide (LM-P)
SEN03953-00
5)
6)
Tighten the 3 mounting bolts of retainer

(30) evenly.
3 Retainer mounting bolt:
19.6 10% Nm {2 10% kgm}
Measure clearance (a) between retainer
(30) and front frame with a clearance
gauge, and then select shims so that the
maximum clearance will be less than 0.1
mm when the shims are inserted.
q
q
0.1 mm, 0.5 mm, 1.0 mm
AJF00741
4)
Press fit dust seal (32) to retainer (30).

7)
9JF00913
Insert selected shim (31) and tighten

retainer (30) with the 6 mounting bolts.
2 Mounting bolt:
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
50-400

SEN03953-00
3.
Assemble the lower hinge of the front frame.

1) Using tool Y4, press fit bearing (27a) and
spacer (27b) to the front frame.
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 a clearance will
not be made between the bearing and
frame.
2 Bearing: Grease (G2-LI)
3)
Press fit dust seal (26) to retainer (24).

4)
Tighten the 3 mounting bolts of retainer

(24) evenly.
3 Retainer mounting bolt:
19.6 10% Nm {2 10% kgm}
Measure the clearance between retainer
(24) and front frame with clearance gauge
[6], and then select shims so that the maximum clearance will be less than 0.1 mm
when the shims are inserted.
q
q
0.1 mm, 0.5 mm
5)
2)
Press fit dust seal (23) to the front frame.

AJF00739
50-400
10

6)
Insert selected shim (25) and tighten the 9

mounting bolts.
2 Mounting bolt:
3 Mounting bolt:
98 123 Nm {10.0 12.5 kgm}
SEN03953-00
q

again.
5

fuel, coolant and lubricants):
Only necessary quantity
AJF00747
50-400
11

Removal and installation of counterweight
SEN03953-00

counterweight
5.
Open the radiator grille and sling it temporarily.
6.
Open the engine left side cover and disconnect

wiring connector CN-BR1 (8).
7.
Disconnect both damper gas cylinders (9).
8.
Remove the 4 mounting bolts and lift off the

radiator grille (10).
Removal
k

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).
3.
Disconnect battery terminals (5) and (6) from

the left side.
4.
Disconnect wiring harness connector CN-R22

(7).
50-400
12
Radiator grille: 25 kg

Removal and installation of counterweight
9.
SEN03953-00
Sling counterweight (11) temporarily and

remove the mounting bolt, and then remove
counterweight (11).
[*1]
4
Counterweight and
assembly: 2,100 kg
batteries
(both)
Installation
q

removal.
[*1]
Mounting bolt:
824 1,030 Nm {84 105 kgm}
50-400
13
SEN03953-00

2008 KOMATSU
All Rights Reserved
50-400
14
SEN03954-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
50

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
50-500
SEN03954-00

Removal and installation of HST pump and 4-gear pump assembly
Removal and installation of HST

pump and 4-gear pump assembly 1
Removal
k
k
a
a
Disconnect the following tubes and hoses.

q
(1): 4 HST pump discharge hoses
q
(2): Hose between charge valve port (A)
and fan motor (IN) hose

Slowly loosen the oil filler cap of the
hydraulic tank to release the residual pressure in the hydraulic tank.
Plug the disconnected hoses to prevent oil
leakage.
Put tags to the disconnected hoses and pipes
and record the installed positions etc. on them.
the atmosphere.
person.
1.
2.
Drain the hydraulic oil.

6
3.
4.
q
q
q
q
q
q
(3): Hose between charge valve port (P)

and brake/fan pump
(4): 2 HST filter hoses
(5):
(6):
(7):
(8):
Steering pump suction tube

HST pump port (G) hose
HST pump port (S) hose
Parking brake solenoid port (T) hose
[*1]
Hydraulic tank: 89 l
Remove the operator's cab assembly. For

details, see Removal and installation of operator's cab.
50-500

q
q
q
(9), (10): HST pump port (PS) hose

(11), (12): HST pump port (YS) hose
(13): HST pump port (G) hose
6.
SEN03954-00
Sling HST pump and 4-gear pump assembly
(22) temporarily, and then remove its 5 mounting bolts and it.
[*2]
4
q
q
q
q
q
q
q
5.
HST pump and 4-gear pump assembly:

150 kg
(14):
(15):
(16):
(17):
HST motor M1 port (T2) hose

HST motor M2 port (T2) hose
Steering priority valve port (P) hose
Hose between work equipment
pump and cut-off valve port (P)
(18): Transfer clutch valve port (T) hose
(19): Transfer lubrication hose
(20): Transfer cooler inlet hose
Disconnect wiring connector (T05) (21).
50-500
SEN03954-00

Installation
q

removal.
[*1]
not enter them.
3 Threaded part of hose (M16 1.5):
12 15 Nm {1.2 1.5 kgm}
20 25 Nm {2.0 2.5 kgm}
30 35 Nm {3.0 3.5 kgm}

1.
If boss (23) was removed from the HST pump

assembly, install it according to the following
procedure.
a Install boss (23) so that it will be flush with
the shaft end of pump (24).
q
Level difference between boss and pump
shaft end: Max. 0.5 mm
2.
Tighten mounting bolt (25) of boss (23).

3 Mounting bolt: 210 Nm {21.4 kgm}

again.
[*2]
2
3
Mating face of pump:

Gasket sealant (LG-6)
Mounting bolt:
A: 245 309 Nm {25.0 31.5 kgm}
B: 98 123 Nm {10.0 12.5 kgm}
50-500

Disassembly and assembly of HST pump assembly

HST pump assembly
SEN03954-00
2.
1
Low pressure valve assembly

1) Remove low pressure valve assembly (2).
a Do not change adjustment screw.
Symbol
Part No.
1 790-201-2720
Part Name
Push tool
Necessity
Q'ty
New/Remodel
Sketch
Special tools
q 1
790-201-2730
Push tool
t 1
790-201-2830
Push tool
t 1
3 790-201-2740
Push tool
q 1
S 2
Disassembly
a
a
1.
If the pump body is disassembled, the assembly special tool will be required. See Assembly
3. 5).
General view
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 Orings and backup rings.
2)
Disassemble the low pressure relief valve

according to the following procedure, if
necessary.
a Before loosening the adjustment
screw, check the adjustment dimension.
i) Remove spring (3) and spring seat
(4).
ii) Remove piston (5).
iii) Remove locknut (6).
iv) Remove adjustment screw (7) from
holder (8).
CJW11904
50-500

SEN03954-00
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)
50-500
Disassemble the high pressure cut-off

valve according to the following procedure, if necessary.
a Before loosening the adjustment
screw, check the adjustment dimension.
i) Remove spring seat (10) and spring
(11) from the pump case.
ii) Remove barrel assembly (12) from
the pump case.
iii) Remove spring seat (13) and shuttle
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).
4.
Remove speed-related valve (DA valve) assembly

1) Remove speed-related valve assembly
(19).

5.
Directional solenoid valve (34)

1) Remove directional solenoid valve assembly (34).
SEN03954-00
3)
Disassemble the valve housing assembly

(35) according to the following procedure.
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 directional 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).
50-500

SEN03954-00
6.
Charge pump assembly (44)

1) Remove 4 mounting bolts (97) and charge
pump assembly (44).
2) Remove wear plate (43).
3) Remove gear (46).
4) Remove coupling (48) and key (49).
a Do not remove bearing metal (47) from
flange (45).
7.
Port plate assembly (51)

1) Mark the position (angle) of the indexing
screw (50), m0.
a Record setting measure.(angle)
2) Set the indexing screw to disassembly
position (a).(0.)
CJW12131
50-500
3)
4)
Mark position of the port plate, m1.

Loosen port plate fixation.
5)
Lift off port plate assembly (51) and control plate (52).

8.
SEN03954-00
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 assembly (54).
50-500
SEN03954-00
4)
Disassemble cylinder block and piston

assembly (54) according to the following
procedure.
i)
ii)
50-500

10
Remove the assembly of pistons (57)

and retainer (58) from cylinder block
(56).
Remove 9 pistons (57) from retainer
(58).

iii)
Remove retainer guide (59) from cylinder block (56).

iv) Remove shim (60) and spring (61).
SEN03954-00
a
Check of pistons
q
Check that there are no scratches or
metal deposits on sliding surface (b),
and there is no axial play (c), (otherwise: pistons must be replaced in
sets).
CJW12142
Check of cylinder block and control plate.

Cylinder bores (d), splines (e).
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 cylinder block.
k Snap ring (63) will jump out. Take
care.
vi) Remove spring (62) and 2 shims (65).
Cylinder surface ( f ) free of scoring.

Control plate (g) without scoring.
Fit faces (f) and (g) (having notch (B) on
the ellipse) together.
q
q
50-500
11
SEN03954-00
9.
Seal
1) Protect drive shaft (66).
3)
4)
Screw [1] in sheet metal screw into the

holes fitted with rubber.
Pull out shaft seal (68) with pliers.
5)
50-500
12

10. Drive shaft assembly

1) Remove drive shaft assembly (66) with
plastic hammer strokes.
2)
Disassemble the drive shaft assembly

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.

SEN03954-00
11. Swivel cradle (73), Bearing cups (74)

1) Remove swivel cradle (73).
2) Remove bearing cups (74).
a Check
q
Bearing cups set.
4)
3)
Bearing surfaces ( j ) of cradle (76).
Remove lever (75) from cradle (73).

a Check of cradle lever (75)
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
q
Check of cradle (76)

Sliding surface (h) free from scoring.
50-500
13
SEN03954-00
3)
4)
Mark position m2, m3 of covers (80), (81),

note measure of zero position ( k ) .
Loosen nut (79).
5)
Remove covers (80) and (81).
6)
Remove O-rings (101) from both sides.

7)
Remove servo piston assembly (82).
Check of groove (A).
8)
Disassemble servo piston assembly (82)

a Disassemble either side first, then
disassemble 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).
v) Remove collar (83).

vi) Remove large spring (87) and small
spring (88).
vii) Remove collar (89).
50-500
14

viii) Disassemble the opposite side similarly.

ix) Remove rod (91) from piston (90).
SEN03954-00
Assembly
a
a
a
1.
Clean the all parts and remove burrs, etc.

Coat the rotary parts and sliding parts with
engine oil (EO10-CD) before installing.
If the tightening torque of a mounting bolt, nut,
or plug is not shown in this manual, see the
tightening torque table.
Pump case
1) Install guide ring (92).
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).
3)
Install seal ring (93) over 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).
50-500
15

SEN03954-00
a
a
2.
The deformation of the seal has

to be done with care so as not to
damage the sealing edges.
Check the position of seal ring
(93). If necessary, straighten
using a finger.
v)
vi)
vii)
viii)
ix)
x)
Using tool S1, push collar (83).

Install ring (84).
Install new plastic cap (86).
Turn over upside down.
Assemble the opposite side similarly.
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)
4)
5)
Insert guide thorn [4] into the servo piston

assembly (82).
Grease slightly guide thorn [4].
Install servo piston assembly (82) with
guide thorn [4].
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).
50-500
16
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.

3.
Cradle, Bearing cups

1) Insert bearing cup set (74a).
a Fit hole (c) of cup set (74a) to the pin
in the case.
2)
SEN03954-00
3)
Swivel cradle (73)

Assemble bearing (74b), wire (95), lever
(75) and articulating pin (96) to cradle
(76).
Insert completely swivel cradle (73) into

housing.
a Assistance: Devices, e.g. clamp, rubber rings, grease and string.
a Pay attention for correct seat of
swivel cradle (73) in the housing.
Sliding stone guidance in piston (82).
Remove auxiliary device.
Completed cradle holding device
50-500
17

SEN03954-00
a
q
Check: Location of the swivel bearing

in the bearing.
Centralize swivel (73) by using a
measuring device (dial gauge or
depth measurement [5])
Check points 1 and 2 they should
have the same dimension.
CJW11961
CJW11958
6)
k
4)
Hold swash plate in position utilizing the

seat screw.
Do not use force.
Fit joint pin (78) and plug (77).

a Pinch wire (95) in pin (78).
CJW11960
5)
50-500
Make holding devices [6] (2 pieces).

a Holding device [6] swivel cradle
18

7)
Install second holding device [6] diagonally and fix the swash plate.
SEN03954-00
a
6)
4.
Drive shaft assembly

a Install the bearing to the shaft in the correct direction.
1) Install the ring to the shaft first, and then
install the bearing to the shaft.
2) Using tool S2, press fit bearing (71) to
drive shaft (72).
3)
4)
5)
Install drive shaft assembly (66).

7)
8)
9)
Before setting seal (68), perform the following procedures.

Measure depth (d1) to the groove bottom
of snap ring (67).
Make a mark of the insertion depth of
push tool S3 (finishing position) (m4 = d1)
on push tool S3.
Using tool S3, press fit seal (68).
a Threads of shaft: 5/8-11UNC-2B,
Thread depth: 36 mm
50-500
19
SEN03954-00
5.

Cylinder block, Piston assembly

1) Assemble the cylinder block and piston
CJW11921
50-500
20

SEN03954-00
i)
Install 2 shims (65) and spring (62) to

the cylinder block.
ii) Compress spring (62) and install snap
ring (63).
iii) Install spring (61) and shim (60) to
cylinder block (56).
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.
iv) Install retainer guide (59).
CJW12142
6.
v) Install 9 pistons (57) to retainer (58).

vi) Install piston and retainer assembly to
cylinder block (56).
a Oil piston and piston pad.
2)
Remove holding device [6].

a Fit cylinder completely with pistons
and retaining device.
3)
Assembly aid:
Hold the cylinder block and piston assembly (54) by using an O-ring (96).
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.
50-500
21

SEN03954-00
a
Indexing screw basic setting - indexing

screw (50) (The end is eccentric.)
Dimension (m): 20 0.75 mm
7.
1)
2)
Press cylinder block (56) to the bottom.

Screw in indexing screw (50).
a Groove in mounting position.
(The groove is directed up in the following figure.)
Port plate (51)

1) Assemble port plate (51), matching (m1).
k Spring preloaded!
2) Insert port plate assembly (51) into housing, guidance with 2 guide bolts [1] that
screwed opposite angle.
3)
3)
a
50-500
Locking screw (50) - Observe adjusting

measure, the angle (m0).
Insert control plate (52) - clockwise rotation.

Insert the control plate so that notch (B)
will not be seen.
22

8.
Servo piston cover

1) Install servo piston covers (80) and (81) to
both sides match mark position (m2),
(m3).
a Cover (80) will be removed because
of filling oil.
SEN03954-00
10. Directional solenoid valve (34)
1) Assemble valve housing assembly (35)
i) Install plug (42) to housing.
2 Threads of plug:
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).
50-500
23
SEN03954-00
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 cutoff 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
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 measured before disassembly.
50-500
24

13. Low pressure relief valve assembly

1) Assemble the low pressure relief valve
i) Install adjustment screw (7) to holder
(8).
ii) Install locknut (6).
iii) Install piston (5).
iv) Install spring seat (4) and spring (3) to
the pump case.
SEN03954-00
14. High pressure relief valve assembly
Fit the O-ring and install 2 high pressure relief
valve assemblies (1).
3 High pressure relief valve assembly:
200 10 Nm {20.39 1.02 kgm}
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 assembly: 70 Nm {7.14 kgm}
50-500
25
SEN03954-00
16. Servo piston cover (80)
1) Install servo piston cover (80) to match
mark position (m3).
2) Adjust zero position according to measure, (k).
k Adjustments of the correct zero position to be carried out after installation
into the machine or on the bench test.
50-500
26

17. Before starting

q
Observe the operating instructions before
starting.
q
Check the machine for remarkable faults.
q
Do not operate the machine with defective
instruments, warning lights or control elements.
q
All safety devices must be in a secure
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.

SEN03954-00
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
50-500
27

SEN03954-00
(1) Plugs
i) Plugs with internal hexagon and profile seal ring
Tightening torque
Thread
50-500
Tightening torque
Thread
Nm
kgm
Nm
kgm
M8 x 1
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
28

ii)
SEN03954-00
Plugs with internal hexagon, O-ring

and UNF-, UN- threads to SAE J 514
Tightening torque
Thread
Tightening torque
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
50-500
29

SEN03954-00
(2) SEAL-LOCK - sealing nuts
Tightening torque
Thread
50-500
30
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

SEN03954-00
(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
---
---
50-500
31

Removal and installation of HST motor 1 assembly
SEN03954-00

motor 1 assembly
4.
1
5.
Removal
k
k
a
a
1.

leakage.

6
2.
When the mounting bolts are removed,

emergency circuit (8) may fall since it is
installed to motor 1 with the hose mounting
bolts. Take care.
Disconnect front drive shaft (1) from the transfer side.

[*1]
6.
7.
3.
Disconnect port T1 hose (4) and port T2 hose

(5).
Disconnect port A hose (6) and port B hose
(7).
Disconnect wiring connectors (T06) (2) and

(T11) (3) from HST motor 1.
50-500
32
Support motor 1 assembly (9) with tool [1]

placed on the transmission jack and remove 4
motor 1 mounting bolts.
[*2]
Supporting motor 1 assembly (9) with the
hand, lower the transmission jack gradually to
remove motor 1 assembly (9).
4
Motor 1 assembly: 60 kg

SEN03954-00
Installation
q

removal.
[*1]
Drive shaft mounting bolt:

59 74 Nm {6.0 7.5 kgm}
[*2]
Motor 1 assembly mounting bolt:

245 309 Nm {25.0 31.5 kgm}

again.
5
50-500
33

SEN03954-00

motor 2 assembly
5.
Disconnect port A hose (6) and port B hose

(7).
6.
Support motor 2 assembly (8) with tool [1]

placed on the transmission jack and remove 4
motor 2 mounting bolts.
[*2]
7.
Supporting motor 2 assembly (8) with the

hand, lower the transmission jack gradually to
remove motor 2 assembly (8).


leakage.
1.

6
2.
Disconnect port T1 block and hose (4) and port

T2 block and hose (5).
Removal
k
4.
Disconnect front drive shaft (1) from the transfer side.

[*1]
3.
Motor 2 assembly: 60 kg
Disconnect wiring connectors (T07) (2) and

(T10) (3) from HST motor 2.
50-500
34

SEN03954-00
Installation
q

removal.
[*1]
Drive shaft mounting bolt:

59 74 Nm {6.0 7.5 kgm}
[*2]
Motor 2 assembly mounting bolt:

245 309 Nm {25.0 31.5 kgm}

again.
5
50-500
35

Disassembly and assembly of HST motor assembly
SEN03954-00

HST motor assembly
2.
1
EP servo valve assembly and cover (HST

motor 1)
Symbol
Part No.
4 02010-20783
790-201-2740
S
5 793T-417-1120
02010-20783
Part name
Bolt
Push tool
Push tool
Bolt
Necessity
Q'ty
New/Remodel
Sketch
Special tools
q
t
q
q
CJW12101
1
1
1
1
Disassembly
1.
Seal
1) Protect drive shaft (1) with a tape etc.
2) Remove snap ring (2) and shim (3).
CJW11980
1)
3)
4)
Remove 4 mounting bolts and solenoid

valve and housing assembly (5).
a Take care of the spring which may
jump out.
Tighten screws [1] into the holes of shaft

seal (4) blocked with rubber.
Pull out shaft seal (4) with pliers.
CJW11982
CJW11981
50-500
36

2)
3)
4)
SEN03954-00
Remove spring seat (7) and spring (8)

from port plate (6).
Remove spring seat (9) and spring (12).
6)
Cover
1] Remove cover (25).
2] Remove plug (26) from cover (25).
CJW11987
CJW11983
3.
5)
Disassemble the solenoid and housing

assembly (5).
1] Remove caps (14), coil (15) and snap
ring (16) of the solenoid in order.
HA servo valve and directional shuttle valve

assembly and flushing valve assembly
(HST motor 2)
CJW12104
CJW12163
2]
3]
a
4]
a
Remove spool (18) and bushing (19)

from housing (13).
Remove pin (20).
Do not remove nut (21) and screw
(22).
Remove plugs (24) from housing
(13).
Do not remove plug (23).
CJW12103
50-500
37
SEN03954-00
1)
Remove the 4 mounting bolts and solenoid valve and housing assembly (27)
a Take care of the spring which may
jump out.

4)
CJW12105
2)
3)
Disassemble 2 solenoids and housing

assembly (27).
1] Remove caps (36) and (37), coils (38)
and (39), and bushing (40) of the
solenoid in order.
CJW12106
Remove spring seat (29) and spring (30)

CJW12125
Disassemble the housing assembly

2] Remove snap ring (43), control bushing (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

4]
5]
a
SEN03954-00
Remove control piston (49) and

spring (50) from housing (35).
Remove plug (51).
Do not remove 5 plugs (52).
CJW12107
5)
Remove flushing valve assembly (53)

CJW12112
50-500
39

SEN03954-00
6)
Disassemble flushing valve assembly (53)

1] Remove plug (54).
2] Remove spring (55), plunger (56), orifice (57), and snap ring (58).
3] Remove 2 plugs (59).
4] Remove spring (60), spring seat (61),
and spool (62).
5] Remove plug (63).
6] Remove guide (64), orifice (65), and
guide (66).
CJW12164
50-500
40

4.
SEN03954-00
Preparation of removal of port plate assembly (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)
2)
3)
4)
5)
Loosen locknut (68) and remove Minimum

Push piston (69) to set the angle of rotary
group (70) to 0.
Break and remove plastic cap (71) and
check installed dimension (b) of Maximum
Remove Maximum Flow Rate Adjustment
screw (96).
a Plastic cap (71) is used to prevent
rusting. Since a spare for it is not supplied, apply paint or take another rustpreventive measure after assembling.
Insert screw [6] to Maximum Flow Rate

Adjustment screw and fix rotary group
(70).
Screw [6]: M12 100 mm or longer.
CJW12126
50-500
41

SEN03954-00
7)
8)
Make match marks (c) between port plate

(6) and housing (82).
Remove port plate assembly (6).
CJW12115
5.
Check of port plate

q
Sliding surface and side guides free
of scoring and no wear.
CJW12002
Disassemble port plate (6) assembly according

1) Remove control lens (80).
2) Remove bolt (73) and piston (74).
a Do not remove screw (76), rod (72), and
piston (69).
Check of control plate

Faces smooth and even, free of cracks
and scoring.
CJW12039
CJW12113
6.
3)
4)
5)
Screw a bolt of M4 and pull out valve

guide (77).
Remove poppet (78).
Remove valve seat (79).
Removal of shaft and rotary group assembly (81)

1) Remove O-ring (75).
2) Screw [2] in threaded pin into center pin
(d).
a Fix the cylinder with disc and locknut.
q
Screw size: M6 92 mm
3) Remove screw [6].
CJW12119
CJW12127
50-500
42

4)
SEN03954-00
a
Push the shaft end with a press to remove

shaft and rotary group assembly (81) from
housing (82).
k If the bearings are used again, do
not hit on the drive shaft.
Check of housing
q
Sliding surface and slide guides
free of scoring and no wear.
CJW12008
CJW12005
a
a
If a press is not available, push the shaft

end with tool [3] or [4] to remove rotary
group assembly (81).
7.
Since shaft and bearing are used as

an assembly, do not remove the bearing.
Disassembly of rotary group assembly (70)

1) Remove screw [2].
2) Remove cylinder block (83).
CJW12006
CJW12009
3)
Remove shim (84) from cylinder block

(83).
CJW12007
CJW12011
50-500
43
SEN03954-00
a

Check of cylinder block (83)

Bores free of scoring, no evidence of wear.
Check of piston and center pin

q
No scoring and no pittings.
CJW12014
CJW12010
a
4)
5)
Remove retaining ring assembly (85).

a Screws are glued. Warm it up to max.
120C and remove with Torx-tools.
Remove 7 pistons (86), spring (87), and
center pin (88) from shaft and bearing
assembly (89).
Do not disassemble the drive shaft and

bearing assembly (89). (If the drive shaft
and be ar i ng a ss e mb ly i s de fe c ti ve ,
replace it whole.)
CJW12116
CJW12128
Check of retaining ring (85)

No scoring and no evidence of
wear.
CJW12013
50-500
44

SEN03954-00
Assembly
a
a
a
1.
4)
Clean the all parts and remove burrs, etc.

Coat the rotary parts and sliding parts with
engine oil (for details, see Table of fuel, coolant and lubricants) before installing.
or plug is not shown in this manual, see the
CJW12022
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).
2) Install retaining ring assembly (85) with
the screw.
a For the tightening torque of the screw,
see Tightening torque table.
5)
CJW12128
3)
Insert shim (84), center pin (88), and piston (86) in cylinder block (83).
a Make sure all parts are fitted in correctly.
Insert the piston to the end of cylinder

block (83) and secure it with screw [2].
Set bolt S4 to the shaft and rotary group

assembly (81) and protect the drive shaft
by type.
a Threads of shaft: 7/16-14UNC-2B,
Thread depth: 28 mm
CJW12169
2.
Installation of rotary group assembly

1) Heat housing (82) to 80C.
CJW12024
CJW12021
50-500
45

SEN03954-00
2)
Insert shaft and rotary group assembly

(81) into housing (82) to seat position.
3.
Port plate assembly (6)

1) Assemble port plate assembly (6) according to the following procedure.
1] Install valve seat (79).
2] Install poppet (78).
3] Install valve guide (77).
CJW12117
CJW12119
3)
4)
5)
Insert screw [6] (M12 100 mm or

longer). (Fix the tapered part of cylinder
block (83) and set the angle to 0.)
Remove screw [2].
Install O-ring (75) to the housing.
a
4]
5]
Piston (69), rod (72) and screw (76)

are already in the port plate (6).
Install piston (74) and bolt (73).
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

a
2)
SEN03954-00
Take care of assembly design!

Install port plate assembly (6) to housing
(82), matching marks (c) made when it
was removed.
CJW12122
CJW12115
4.
Installation of Minimum Flow Rate Adjustment 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 position.
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.
50-500
47

SEN03954-00
5.
HA servo valve and directional shuttle valve

assembly and flushing valve assembly (53)
(HST motor 2)
1) Assemble the flushing valve assembly
1] Install guide (66), orifice (65), and
guide (64).
3 Guide (66): 3 Nm {0.31 kgm}
3 Guide (64): 8 Nm {0.81 kgm}
2] Install plug (63).
3 Plug:
29 38 Nm {2.96 3.89 kgm}
3]
4]
5]
6]
Install spool (62), spring seat (61),

and spring (60).
Install 2 plugs (59).
3 Plug: 40 Nm {4.1 kgm}
Install snap ring (58), orifice (57),
plunger (56), and spring (55).
Install plug (54).
3 Plug: 50 Nm {5.1 kgm}
CJW12164
50-500
48

2)
SEN03954-00
Install flushing valve assembly (53) to port

plate (6).
3 Plug:
55 60 Nm {5.61 6.12 kgm}
6]
a
CJW12112
3)
Install 2 solenoids to housing (35).

Install bushing (40), coils (39) and
(38), and caps (37) and (36) of the
solenoid in order.
CJW12106
Assemble housing assembly (27) according 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 housing (35).
CJW12107
4)
5)
3]
4]
5]
Install pin (46).

Install control piston (45) and control
bushing (44).
Install spring (34) and spring seat (31) to

the port plate.
Install spring (30) and spring seat (29).
CJW12125
CJW12108
50-500
49
SEN03954-00
6)
Install solenoid valve and housing assembly (27) with the 4 mounting bolts to port
plate (6).

2)
Assemble housing assembly (5) according

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}
2] Install cover (25).
3 Mounting bolt:
39 49 Nm {4.0 5.0 kgm}
4]
Install snap ring (16), coil (15), and

cap (14) in order to housing assembly
(13).
CJW12102
CJW11987
50-500
50

3)
4)
5)
SEN03954-00
Install spring (10) and spring seat (11) to

port plate (6).
5)
6)
Protect drive shaft (1) with a tape etc.

CJW11980
CJW11983
8.
6)
Install solenoid valve and housing assembly (5) with the 4 mounting bolts.
Filling with oil

Fill up hydraulic aggregates with medium
before start-up.
CJW12036
CJW11982
7.
Seal (Common to HST motors 1 and 2)

1) Before setting seal (4), measure depth (f)
to the groove bottom of snap ring (2).
2) Make a mark of insertion depth (e) of push
tool S5, (f) + thickness of shim (3), on
push tool S5.
3) Using push tool S5, press fit seal (4).
4) Install shim (3).
CJW12170
9.
a
Tightening torque table

or plug is not shown in this manual, see Disassembly and assembly of HST pump assembly,
Tightening torque table.
10. Before starting

a Observe the operating instructions before
starting.
q
Check the machine for remarkable faults.
q
Do not operate the machine with defective
instruments, warning lights or control elements.
q
All safety devices must be in a secure
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
51
SEN03954-00

Removal and installation of work equipment control valve assembly
Removal and installation of work

equipment control valve
assembly
3.
1
Removal
k
k
k
1.
2.
Stop the machine on a level place and,

apply the parking brake, and put chocks
under the tires.
Support the lift arm securely.
Stop the engine, and then slowly loosen the
oil filler cap of the hydraulic tank to release
the residual pressure in the hydraulic tank.
Operate the work equipment control lever 2
3 times to release the residual pressure in
the work equipment circuit.
Raise the lift arm, dump the bucket, and support the lift arm with support stand [1] and
square bar [2].
Remove the work equipment control valve upper

cover (1).
50-500
52
Disconnect the following hoses and tubes. [*1]

a Mark all the hoses and tubes with tags to
prevent mistakes in the mounting position
when installing.
leakage.
a Since oil will leak through the disconnected hoses and tubes, prepare oil
receivers.
q
(2): Port A1 hose
q
(3): Port B1 hose
q
(4): Port A2 tube
q
(5): Port B2 tube
q
(6): Bucket DUMP PPC hose
q
(7): Bucket TILT PPC hose
q
(8): Lift arm LOWER PPC hose
q
(9): Lift arm RAISE PPC hose
q
(10): Port P hose
q
(11), (12): Port T hoses
Reference: This is the view from the rear lower

part of the work equipment control valve.

Removal and installation of work equipment control valve assembly
4.
Remove 3 mounting bolts (13) and move work

equipment control valve (14) toward you.
SEN03954-00
Installation
q

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 corresponding 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: Monolever (If equipped)
5.
Lift off work equipment control valve assembly

(15).
4
Work equipment control valve assembly: 65 kg
No.
Connecting point
Band color
(6)
Bucket DUMP
Blue
(7)
Bucket TILT
Red
(8)
Lift arm LOWER
Orange
(9)
Lift arm RAISE
Yellow

again.
5

50-500
53

Removal and installation of hydraulic tank assembly
SEN03954-00

hydraulic tank assembly
4.
Remove tube (4) from the hydraulic oil filter.
5.
Remove hydraulic oil filter cover mounting

bolts (5) and move hydraulic oil filter and cover
assembly (6) and its hoses to under the operator's cab.
6.
Disconnect 8 hoses (7), (8), (9), (10), (11),

(12), (13), and (14) from the hydraulic tank. [*1]
Removal
k
k
a
a
1.

Operate the work equipment control lever 2
3 times to release the residual pressure in
the work equipment circuit.
leakage.
Remove hydraulic tank upper cover (1).
k Slowly loosen the oil filler cap of the
hydraulic tank to release the residual
pressure in the hydraulic tank.
2.
Remove cab right undercover (2).
3.
Remove right side fender (3).

4
50-500
Fender: 35kg
54

Removal and installation of hydraulic tank assembly
7.
Sling the hydraulic tank assembly temporarily

and remove 1 upper mounting bolt and 2 lower
mounting bolts (15).
[*2]
SEN03954-00
Installation
q

removal.
[*1]
Inserting parts of hoses (6) and (7):

Gasket sealant (ThreeBond 1206E or
equivalent)
Hose clamp: 8.8 0.5 Nm {90 5 kgcm}
[*2]
8.
Lift off hydraulic tank (16) and ladder together.

4
Hydraulic tank and ladder assembly:

210 kg (including hydraulic oil)
Hydraulic tank mounting bolt:

98 123 Nm {10.0 12.5 kgm}

again.
5

50-500
55

Disassembly and assembly of hydraulic cylinder assembly
SEN03954-00

hydraulic cylinder assembly
Disassembly
1
1.
Cylinder assembly
Set cylinder assembly (1) to tool U1.
2.
Cylinder head and piston rod assembly

(Steering cylinder)
1) Using tool U2, remove cylinder head (2)
from the cylinder.
790-502-1003
Repair stand
t 1
790-101-1102
Hydraulic pump
t 1
1
790-102-2303
2 or
790-102-3802
Wrench assembly
t 1
(for steering)
3 790-302-1340
Socket (for steering) t 1
t 1
790-201-1702
Push tool kit
790-101-5021
Grip
01010-50816
Bolt
Push tool (lift)
790-201-1831
Push tool
(bucket)
790-201-1741
Push tool
(steering)
790-201-1500
Push tool kit
t 1
790-101-5021
Grip
01010-50816
Bolt
790-201-1630
Plate (lift)
790-201-1640
Plate (bucket)
790-201-1550
Plate (steering)
4 790-201-1821
Sketch
Part Name
New/Remodel
Part No.
Q'ty
Symbol
Necessity
Special tools
2)
Pull cylinder head and piston rod assembly (3) out of cylinder (4).
a Since oil will flow out when the piston
rod assembly is pulled out of the cylinder, prepare an oil receiver.
Expander
q 1
796-720-1680
Ring (lift, bucket)
q 1
07281-01589
Clamp
(lift, bucket)
q 1
796-720-1740
Ring (steering)
q 1
07281-00809
Clamp (steering)
q 1
790-102-4300
Wrench assembly
t 1
(lift, bucket)
790-102-4310
Pin
6 790-720-1000
50-500
56
t 2

3.
Cylinder head and piston rod assembly

(Bucket cylinder and lift cylinder)
1) Remove the mounting bolt of cylinder
head assembly (2).
q
Width across flats of bolt: 24 mm
2)
SEN03954-00
4.
Piston and cylinder head (Steering cylinder)

1) Set cylinder head and piston rod assembly
(3) to tool U1.
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).
Pull cylinder head and piston rod assembly (3) out of cylinder (4).
a Since oil will flow out when the piston
rod assembly is pulled out of the cylinder, prepare an oil receiver.
50-500
57
SEN03954-00
5.
Piston and cylinder head (Bucket cylinder

and lift cylinder)
(3) to tool U1.
2) Remove lock screw (18) of the piston
assembly.
a Screw size: M12 x 1.75
a If screw (18) is so caulked that it cannot 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).

6.
Disassembly of piston assembly

1) Remove wear ring (9) and piston ring (10)
from piston (8).
2)
50-500
58
For only the bucket cylinder and lift

cylinder.
Remove O-ring and backup ring (11) from
position (8).

7.
Disassembly of cylinder head assembly

1) Remove O-ring and backup ring (15).
2) Remove snap ring (16) and dust seal (17).
3) Remove rod packing (18).
4) Remove buffer ring (19).
5) Remove bushing (20).
6) Remove O-ring (21). (For only the steering
cylinder)
a Bucket cylinder and lift cylinder
SEN03954-00
Assembly
a
a
1.
Take care not to damage the packings, dust

seals, O-rings, etc.
Do not insert each backup ring forcibly, but
warm it in water at 50 60C and then insert it.
Assembly of cylinder head assembly
1) Using tool U4, press fit bushing (20).
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.)
Steering cylinder
50-500
59
SEN03954-00
2.
Assembly of piston assembly

1) Using tool U6, expand piston ring (10).
a Set the tool to the piston ring and turn
its handle by 8 10 turns to expand
the piston ring.

3.
Assembly of cylinder head and piston rod

assembly (Steering cylinder assembly)
(3) to tool U1.
2) Install cylinder head assembly (2) and piston assembly (6) to the piston rod.
3) Using tool U3, tighten nut (5) to the specified 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

Nut (Steering):
785 78.5 Nm {80 8.0 kgm}
2)
3)
4)
Remove piston ring (10) from tool U6 and

install it to piston (8).
Using tool U7, shrink piston ring (10).
Install wear ring (9).
4.
5)
50-500
For only the bucket cylinder and lift

cylinder.
Install backup ring and O-ring (11).
60
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
3) Using tightening tool U8, tighten piston
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 procedure.
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

SEN03954-00
5.
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).
Diameter of Depth of tap

tap drill hole
drill hole
10.3
Cylinder head (Steering cylinder)

1) Set cylinder (4) to tool U1.
2) Sling cylinder head and piston rod assembly (3) and install cylinder (4).
27
Tap to be
used
Tapping
depth
12 X 1.75
20
3)
4)
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}
Using tool U2, install cylinder head

assembly (2) to the cylinder.
3 Cylinder head:
539 54.0 Nm {55 5.5 kgm}
Remove cylinder assembly (1) from tool
U1.
50-500
61
SEN03954-00
6.

Cylinder head (Bucket cylinder and lift cylinder)

1) Set cylinder (4) to tool U1.
2) Sling cylinder head and piston rod assembly (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}
4)
5)
50-500
a For only the bucket cylinder.

Adjust the leveler plate to the following
dimensions and tighten the bolt.
Dimension (a): 48 1 mm
Dimension (b): 119 2 mm
Remove cylinder assembly (1) from tool

U1.
62

SEN03954-00
50-500
63
SEN03954-00

2008 KOMATSU
All Rights Reserved
50-500
64
SEN03955-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
50
600 Work equipment

Removal and installation of work equipment assembly .................................................................................. 2
50-600
600 Work equipment

Removal and installation of work equipment assembly
SEN03955-00
Removal and installation of work

equipment assembly
1.
4.
Sling bucket cylinder assembly (3) temporarily

and pull out rod-side pin (4) to disconnect the
cylinder rod and bell crank.
[*3]
a Install block [1] between the cylinder bottom and frame.
shims.

Bucket cylinder assembly: 130 kg
Sling the bucket link temporarily and remove

bucket link pin (1).
[*1]
4
a
a
2.
Move the machine to the rear and disconnect

the bucket.
Removal
k
3.
Bucket link assembly: 45 kg
Secure the bucket link to the bell crank

with wires, etc.
Record the thickness and quantity of the
shims.
Remove bucket hinge mounting pin (2).

[*2]
k Never insert your fingers in the pin
holes.
shims.
5.
50-600
Set supports [2] under the end of the lift arm

and release the residual pressure in the
hydraulic piping.
600 Work equipment

6.
SEN03955-00
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 axle.
4
Lift cylinder assembly (1 pieces):

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
7.
Disconnect boom kick-out proximity switch

connector CN-F04 (7).
8.
Remove boom kick-out switch (8).
Bucket link assembly: 45 kg
[*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 mounting pin (11).
[*6]
shims.
a
10. Lift off lift arm and bell crank and bucket link
assembly (10).
4
Lift arm and bell crank and bucket link

assembly: 1250 kg
50-600
600 Work equipment

SEN03955-00
14. Pull dust seal (17) and bushing (18) out of lift
arm (16).
[*9]
Installation
q
k
a
a
15. Pull dust seal (19) and bushing (20) out of bell
crank (14).
[*9]

removal.
When starting the engine, check that the
directional lever is in neutral and the parking brake is applied.
When aligning the pin holes, use a bar.
Never insert your fingers in the pin holes.
Apply specified lubricant to the seal so that the
seal will not be damaged when the pin is
inserted.
Supply grease to each pin until it comes out
through the joint.
[*1]
Procedure for installing bucket link pin
1. Sling the bucket link assembly and install cord
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
600 Work equipment

[*2]
Procedure for installing bucket hinge pin
1. Operate the control lever to align the holes for
bucket mounting pin (2) and install cord ring
(25).
2.
Insert a shim in clearance (b).

q
Clearance (b) (On each side): Max. 1.5
mm
q
3.

(26).
holes.
caught.
a Take care not to damage the pin.
a Before installing the pin, apply lubricant to
the inside of the bushing.
2 Inside of bushing and seal:
Lubricant containing molybdenum disulfide (LM-P or equivalent)
a After installing the pin, supply grease.
2 Grease: Hyper White (G2-T) or
equivalent
SEN03955-00
[*3]
Procedure for installing bucket cylinder pin (on
rod side)
a It is not necessary to insert a shim in clearance
(C).
1. Install mounting pin (4) and lock it with bolt
(27).
holes.
2 Inside of bushing:
disulfide (LM-P or equivalent)
3 Grease: Hyper White (G2-T) or equivalent
2.
Adjust the bucket positioner. For details, see

Testing and adjusting, Testing and adjusting
bucket positioner.
50-600
SEN03955-00
[*4]
Procedure for installing lift cylinder pin (on rod
side)
k When starting the engine, check that the
directional lever is in neutral and the parking brake is applied.
1. Insert a shim in clearance (d).
q
Clearance (d) (On each side): Max. 1.5
mm
q
Varieties of shim thickness: Only 1.5 mm
2.

(28).
holes.
equivalent
600 Work equipment

[*6]
Procedure for installing lift arm pin (on frame
side)
1. Insert a shim in clearance (e).
a When installing the right-hand lift arm pin,
fit the boss on the right inside of the frame
to the lift arm boss to eliminate the clearance and insert shims in the clearance on
the opposite side.
a When installing the left-hand lift arm pin,
insert shims evenly on both sides.
q
Clearance (e) (On each side): Max. 1.5
mm
q
2. Install mounting pin (11) and lock it with bolt
(29).
holes.
a Take care not to damage the pin and seal.
equivalent
[*5]
a Adjust the boom kick-out. For details, see Testing and adjusting, Testing and adjusting of
boom kick-out.
50-600
600 Work equipment

[*7]
Procedure for installing bucket link pin
a It is not necessary to insert a shim in clearance
(f).
q
Clearance (f) (On each side): Max. 1.5
mm
a Secure the bucket link to the bell crank with
chains, etc.
1. Install cord ring (30), aligning the holes for
bucket link mounting pin (13).
2.

(31).
holes.
caught.
equivalent
SEN03955-00
[*8]
Procedure for installing bell crank center pin
a It is not necessary to insert a shim.
1. Install the mounting pin and lock with the bolt.
holes.
the inside of the bushing and the seal.
2 Inside of bushing and seal:
Lubricant containing molybdenum disulfide (LM-P or equivalent) or Hyper White (G2-T)
[*9]
a Press fit bushings (18), (20), and (22) to lift arm
(16), bell crank (14), and bucket link (12)
respectively with hydraulic cylinder [3] and
then install dust seals.
2 Bushing: Grease (G2-LI)
a Apply the grease to the seals to prevent their
damages.
a
q
q
Press fit the dust seals with the lips out.

Installed dimension (g): 0.25 0.80 mm
Installed dimension (h): 2 3 mm
Greasing
Supply grease to each pin.
a Supply grease until it comes out of
the joint.
50-600
SEN03955-00

2008 KOMATSU
All Rights Reserved
50-600
SEN03956-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
50

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
50-700
SEN03956-00

operator's cab and floor frame
assembly

Removal and installation of operator's cab and floor frame assembly
3.

4.
Remove right fender (2).

4
Removal
k
Fender: 35 kg

the atmosphere.
person.
1.
The operator's cab of this machine forms one

unit with the floor frame.
Recover the refrigerant (R134a). For details,
see Removal and installation of air conditioner
unit.
[*1]
2.

6
50-700
5.
Remove right covers (3), (4) and (5).
6.
Remove hydraulic tank cover (6).

k Loosen the hydraulic tank cap gradually to release the pressure in the
hydraulic tank.
7.
Disconnect cab ground cable (7) from the

lower right of the floor.
8.

9.
SEN03956-00
Disconnect the following wiring harness connectors 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.
50-700
SEN03956-00

17. Disconnect the following wiring harness connectors from the lower left of the floor.
q
(27): CN-LR1
q
(28): CN-LR10
q
(29): CN-LR2
q
(30): CN-LR3
q
(31): CN-LR12
q
(32): CN-LR4
q
(33): CN-LT1
q
(34): CN-LT12
q
(35): CN-LR7
q
(36): CN-LR11
q
(37): CN-LR6
a Put tags to the disconnected connectors
and record the installed positions etc. on
them.
19. Disconnect 2 washer hoses (41) from the

engine compartment side.
20. Disconnect air conditioner pipes (42) and (43).
[*1]
21. Disconnect heater hoses (44) and (45) from
the engine side.
leakage.
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

23. Disconnect the following hoses from the top of

brake valve (48).
[*3]
q
(49): A port hose
q
(50): B port hose
q
(51): P1 port hose
SEN03956-00
25. Set parking brake lever (53) in the OFF

(Release) position.
26. Remove seat belt mounting bolt (54).
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
28. Loosen locknut (56) and remove pin (57).

29. Pull out grommet (58) and brake cable (59)
together toward under the floor.
AJF00729
50-700
SEN03956-00

30. Remove right and left front mount covers (60).
Installation
q
31. Remove right and left rear fender brackets

(61).
32. Remove right and left front operator's cab

mounting nuts (62).
[*4]
33. Remove right and left rear operator's cab
mounting nuts (63).
[*5]
34. Lift off operator's cab and floor frame assembly

(64).
a Check that all the wiring and piping are
disconnected.
4
Operator's cab and floor frame assembly: 900 kg
AJF00729

removal.
[*1]
not enter them.
3 Apply engine oil (EO15W-40) to threaded
part and seat of mounting bolt.
12 15 Nm {1.2 1.5 kgm}
20 25 Nm {2.0 2.5 kgm}
30 35 Nm {3.0 3.5 kgm}

a Charge capacity: 1,200 50 g
[*2]
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 circuit".
[*4]
50-700
Right and left front operator's cab mounting

nuts (62): 824 1,030 Nm {84 105 kgm}

SEN03956-00
[*5]

again.
5
Right and left rear operator's cab mounting

nuts (63): 824 1,030 Nm {84 105 kgm}
Hydraulic oil (For details, see "Table of fuel,

coolant and lubricants"):

5

(For details, see "Table of fuel, coolant and
lubricants")
50-700

Removal and installation of operator's cab glass (Stuck glass)
SEN03956-00

operator's cab glass (Stuck glass)1
Symbol
Part No.
1 793-498-1120
1 2 793-498-1130
X
3 793-498-1110
2
793-498-1210
Part Name
Clear plate
Plate
Magnet
Lifter (Suction
cups)
Necessity
Q'ty
New/Remodel
Sketch
Special tools
If the glass is narrow, you may cut the

adhesive by the following method. Insert a
fine wire [2] (piano wire, etc.) in the adhesive and grip its both ends with pliers [3],
etc. (or hold them by winding them onto
something) and cut the adhesive with the
wire.
t 2
t 2
t 2
CPW11602
t 2
Removal
a
a
1.
All sides of each glass of the operator's cab of

this machine are stuck.
Remove the window glass to be replaced
Using seal cutter [1], cut the adhesive between

broken window glass (1) and operator's cab
(2).
a
The broken window glass may be

removed with knife [4] and a screwdriver.
(If the screwdriver is applied directly to the
normal window glass, the glass will be
broken.)
When using knife [4], insert a screwdriver
in the cut to widen it and move the knife
forward.
CPW11601
CPW11607
2.
50-700
Remove the window glass.

Installation
1.
SEN03956-00
3.
Using scraper [5], remove the remaining adhesive.

a Do not scratch the paint.
When the adhesive was removed with the

scraper, if any paint was flaked off, coat the
bare part with paint.
a If the glass is installed without repairing
the bare part, that part will be rusted.
a Do not apply paint to a 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
well, the glass may not be stuck perfectly.
a Clean the all black part on the back side of
the window glass.
a After cleaning the sticking surfaces, leave
them for at least 5 minutes to dry.
4.
Stick both-sided adhesive tape (4) along the

inside edge of the glass sticking section.
q
Size of both-sided adhesive tape:
7 4.8 mm
a When sticking the both-sided adhesive
tape, do not touch the cleaned surface as
long as possible.
a Do not remove the release tape of the
both-sided adhesive tape on the glass
sticking side before sticking the glass.
CPW11604
CPW11606
50-700
SEN03956-00
a

Take care the corner (part (b)) of bothsided adhesive tape will not float.
CPW11614
CPW11633
3)
a
When sticking the both-sided adhesive

tape around a side or a rear window glass,
start at center of the top and make a clearance of about 5 mm at end joint (c).
Using tool X2 (suction cups), place window glass (3) on tool X1-1 (5 mm spacer)
and match it to the operator's cab.
CPW11615
CWW11608
4)
5.
Position the replacement glass.

1) Stick X1-2 (thin steel sheet) to tool X1-1
(spacer) with adhesive.
q
Spacer thickness ( t) : 5 mm
2) Match tool X1-3 (magnet) to tools X1-1
and X1-2 and set them to the 2 lower
places of the window glass sticking part of
operator's cab (2).
5)
6)
Check the clearance between window

glass (3) and operator's cab (2) on both
sides and adjust it evenly.
Stick tape [6] between window glass (3)
and operator's cab (2) and draw positioning line (a).
Cut the tape between window glass (3)
and operator's cab (2) with a knife, and
then remove the window glass.
a Do not remove the tapes left on the
window glass and operator's cab
before installing the window glass.
CPW11613
CPW11616
50-700
10

6.
Apply primer.
a The using limit of primer (5) is 4 months
after the date of manufacture. Do not use
primer (5) after this limit.
a Use the primer within 2 hours after
unpacking it.
a Even if the primer is packed again just
after it is unpacked, use it within 24 hours
after it is unpacked for the first time.
(Discard the primer 24 hours after it is
packed.)
1) Stir the primers for paint and glass sufficiently before using them.
a If the primer has been stored in a
refrigerator, leave it at the room temperature for at least half a day before
stirring it.
(If the primer is unpacked just after
taken out of the refrigerator, water will
be condensed. Accordingly, leave the
primer at the room temperature for a
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)
SEN03956-00
a
a
a
Parts to be coated with primer: Apply

the primer all over dimension (d) on
the outside of the both-sided adhesive tape.
q
Dimension to apply primer (d):
23 mm
After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
If the glass primer is applied by mistake, wipe it off with white gasoline.
(If wrong primer is applied, the glass
will not be stuck.)
CPW11610
CWW11624
Evenly apply paint primer (7) to the parts

on the outside of both-sided adhesive tape
(4) on operator's cab (2) which will be
coated with the adhesive.
2 Paint primer: SUNSTAR PAINT
PRIMER 580 SUPRE
a Do not apply the primer more than 2
times.
(If it is applied more than 2 times, its
performance will be lowered.)
50-700
11
SEN03956-00
4)
Evenly apply glass primer (8) to the black

part of window glass (3) to be stuck.
2 Glass primer: SUNSTAR GLASS
PRIMER 580 SUPRE
a Do not apply the primer more than 2
times.
(If it is applied more than 2 times, its
performance will be lowered.)
a Parts to be coated with primer: Apply
the primer to the sticking surface of
window glass (3) and all over dimension (d) on both-sided adhesive tape
(4) and operator's cab (2).
q
Dimension to apply primer (d):
23 mm
a Do not apply the primer to the
boarder about 5 mm wide between
the black part and transparent part of
the glass.
a After applying the primer, leave it for
at least 5 minutes (within 8 hours) to
dry.
a If the paint primer is applied by mistake, wipe it off with white gasoline.
(If wrong primer is applied, the glass
will not be stuck.)

7.
Apply adhesive.
a Use either of the 2 types of the adhesive.
2 Adhesive (Summer):
SUNSTAR PENGUINE
SEAL 580 SUPER S
2 Adhesive (Winter):
SUNSTAR PENGUINE
SEAL 580 SUPER W
a The using limit of the adhesive is 4 months
after the date of manufacture. Do not use
the adhesive after this limit.
a Keep the adhesive in a dark place where
the temperature is below 25C.
a Never heat the adhesive higher than
30C.
a When reusing the adhesive, remove the
all hardened part from the nozzle tip.
1) Break aluminum seal (10) of the outlet of
adhesive cartridge (9) and install the nozzle.
CPW11612
CWW11625
2)
Cut the tip of the adhesive nozzle (11) so

that dimensions ( f ) and (g) will be as follows.
q
Dimension ( f) : 10 mm
q
Dimension (g): 12 mm
CPW11617
CPW11611
50-700
12

3)
SEN03956-00
a
Set adhesive cartridge (9) to caulking gun

[7].
a An electric caulking gun is more efficient.
a
a
CPW11618
Apply adhesive (12) to dimensions (h)

and ( j ) of both-sided adhesive tape
(4) of operator's cab (2).
q
Dimension (h): 10 mm
q
Dimension ( j ) : 12 mm (Approx.
twice a s high as adhes iv e
tape)
Apply adhesive (12) higher than bothsided adhesive tape (4).
Apply the adhesive evenly.
CWW11620
4)
Remove release tape (13) of the bothsided adhesive tape on the glass side.
8.
5)
Apply adhesive (12) to the outside of bothsided adhesive tape (4) of the operator's
cab.
a Before applying the adhesive, check
that the primer is applied to the surface to which the adhesive will be
applied.
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, X12, and X1-3 and set them to the 2 lower
places of the window glass sticking part of
operator's cab (2).
CPW11614
CPW11619
50-700
13
SEN03956-00
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.
a Before sticking the glass, check that
the primer is applied to the surface to
which the glass will be stuck.
CPW11623
9.
CPW11622
Check clearance ( k ) between the

front side of the front glass and each
side and adjust it evenly.
q
Clearance ( k ) : 5 mm
Cure the stuck window glass for a certain time.

a Curing time before removing tool X1-1 (5mm 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
be sealed shown in the figure.
a Stick the masking tapes to both inside
and outside of the operator's cab.
CPW11628
CWW11626
3)
50-700
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 both-sided adhesive
tape.
a Do not press the window glass to
strongly.
14
CWW11629

2)
SEN03956-00
Fill the joint of the glasses with caulking

material (15).
a The usable period 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 window glass.
11. Remove the primer and adhesive from the

operator's cab and window glass.
a Using white gasoline, wipe off the adhesive before it is dried up.
a When cleaning the glass, do not give an
impact to it.
50-700
15
SEN03956-00

Disassembly and assembly of operator's seat assembly
The procedure for disassembling and assembling the operator's seat assembly [air-suspension (manufactured by ISRING HAUSEN is optional.)] is shown below.
A:
B:
C:
Headrest
Back seat
Cushion seat
D:
E:
F:
Left-hand armrest
Suspension cover
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

2)
Apply force (b) to part (a) of each clip (2)

in the direction of the arrow to turn the clip
and release it from part (d) of headrest
stay (1), and then pull out up headrest (3).
SEN03956-00
2.
Back seat
1) Disconnect 3 air hoses (5) from the rear
left of back seat (4).
a Before disconnecting the air hoses, check
their types.
2)
Remove back seat hinge mounting bolt (6)

(M8 bolt).
3)
Bring back seat (4) down forward.
Pushing in both clips (2) simultaneously,

remove headrest (3).
50-700
17
SEN03956-00
4)
5)
6)
Apply force (E) to the right side of back

seat (4) in the direction of the arrow.
Applying the force to back seat (4), pull its
right side up.
Slide back seat (4) sideway and remove it.

3.
Cushion seat
1) Push cushion adjuster lever (7) inward
and slide cushion seat (8) to the front end.
2)
3)
50-700
18
Push cushion slide stopper wire (9) down

with screwdriver [1], etc.
Keeping the state in 2), pull out cushion
seat (8) forward and remove it.

4.
Armrest
The procedure for disassembling left-hand
armrest (10) is shown below.
SEN03956-00
4)
5)
1)
2)
3)
Remove plastic cap (12) from the armrest

hinge.
a Use a flat-head screwdriver, etc. to
remove the cap.
Loosen armrest hinge mounting bolt (13).
6)
Turn left-hand armrest (10) up by 180.

a If the armrest is not turned, you cannot apply the tool to upper mounting
bolt (15B).
Remove plastic cap (14) and upper
mounting bolt (15B).
Remove left-hand armrest (10).

a There are 2 position adjustment
washers (16) installed to each bolt
between the armrest and back seat.
Take care not to lose them.
Remove plastic cap (14), and then remove

lower mounting bolt (15A) (M8 bolt) of lefthand armrest (10).
50-700
19
SEN03956-00
5.
Suspension cover
1) Remove right-hand hinge cover (17).
2) Remove plastic plate (18) from the rear
with screwdriver [1], etc.
a Take care not to damage the plastic
plate by prying it off forcibly with a
screwdriver, etc.
3)
50-700

4)
Remove 4 mounting bolts (20), cushion

rear fixing plate (21), 2 cushion rails (22),
and 4 bushings (23).
5)
Remove 3 metallic suspension cover clips

(24).
Remove 4 suspension cover fixing rings

(19).
20

6)
7)
6.
Remove 6 plastic suspension cover clips

(small) (25) and 2 plastic suspension
cover clips (large) (26).
a Clips (small) (25):
Front upper part; 2 places
Each side; 1 place
Rear lower part; 2 places
Clips (large) (26):
Front lower part; 2 places
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.
SEN03956-00
2)
3)
Slide rails (28) to the rear end.

Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the front part
of each rail.
4)
5)
Slide rails (28) to the front end.

Remove 1 hexagon socket head bolt (29)
and 1 lock washer (30) from the rear part
of each rail, and then remove rails (28).
Rails
1) Turn over the seat assembly to set rails
(28) on the upside.
Take care not to lose height adjustment washers (31) between the rails
and suspension.
50-700
21
SEN03956-00
Assembly
1.
Rails
1) Put height adjustment washers (31) between
rails (28) and suspension, and then set rails
(28) in position.
2)

2.
Suspension cover
1) Set suspension cover (27) in position and
install 6 plastic suspension cover clips
(small) (25) and 2 plastic suspension
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
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)
3)
50-700
Install 3 metallic suspension cover clips

(24).
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}
22

3)
Set 4 bushings (23) and 2 cushion rails

(22), and then install cushion rear fixing
plate (21) and 4 mounting bolts (20).
3 Cushion rail mounting bolt:
21.4 27.6 Nm {2.18 2.82 kgm}
4)
Install 4 suspension cover fixing rings

(19).
5)
6)
Install plastic plate (18) to the rear.

Install right-hand hinge cover (17).
SEN03956-00
3.
Armrest
The procedure for assembling left-hand armrest (10) is shown below.
1)
Install 2 position adjustment washers (16)

for each bolt and set left-hand armrest
(10) in position.
2)
Tighten lower mounting bolt (15A) lightly

and turn armrest (10) by 180.
Tighten upper mounting bolt (15B) lightly.
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}
Install 2 plastic caps (14).
3)
4)
5)
50-700
23
SEN03956-00
6)
7)
4.
Tighten armrest hinge mounting bolt (13).

a Tighten the bolt so that the arm will
move smoothly.
q
Operating effort at armrest end:
49.0 78.4 N {5 8 kg}
Install plastic cap (12).

5.
Back seat
1) Insert the left side of back seat (4), and
then lower and set the right side.
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)
50-700
24
Install back seat hinge mounting bolt (6).

3 Back seat hinge mounting bolt:
21.4 27.6 Nm {2.18 2.82 kgm}

3)
6.
SEN03956-00
Connect 3 air hoses (5) to the rear left of

back seat (4).
Headrest
1) Insert headrest (3) in back seat (4).
a Check that 2 clips (2) on both sides
are locked securely.
50-700
25

Removal and installation of air conditioner unit
SEN03956-00
Removal and installation of air

conditioner unit
5.
Remove wiper blades (13).

rear frames.
the atmosphere.
person.
1.
2.
Drain the coolant.

6
3.
Disconnect wiper water hose (12) from the

front outside of the cab.
Removal
k
4.
CPW11631
6.
Disconnect wiper water hose (14) from the

inside of the cab.
7.
Disconnect wiper wiring harness connector

(15).
8.
Remove wiper motor assembly (16).
CPW11631
[*1]
Remove the monitor panel, referring to the

Removal and installation of monitor panel.
9.
Remove left duct (17) and right duct (18).
CPW11631
50-700
26

10. Disconnect right lower duct hose (19).
SEN03956-00
16. Remove right cover (30).
11. Remove 8 mounting bolts (20) and plate (21).
CPW11631
CPW11631
12. Remove left cover (22).

13. Disconnect the following wiring harness connectors.
q
(23): CN-C50
q
(24): CN-C49
q
(25): CN-AL1
17. Disconnect heater hoses (32) and (33) and air

conditioner pipes (34) and (35) at the lower
right of air conditioner unit (31).
a Plug the disconnected hoses and ports to
prevent foreign matter from entering them.
[*2]
14. Remove air conditioner internal air filter case

(26).
CPW11631
CPW11631
19. Disconnect blower motor wiring harness connector (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
50-700
27

SEN03956-00
20. Remove air conditioner assembly (31) upward.
a Check that all the wiring and piping are
disconnected.
3)
Remove air conditioner external air duct

(42) from the lower left of the floor.
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 external 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
50-700
28
CPW11631

CPW11631
SEN03956-00
[*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:
Compressor oil for R134a (SANDEN: SP10 or equivalent)
3 Hose adapter mounting bolt (44):
8 12 Nm {0.8 1.2 kgm}
CPW11631
Installation
q

removal.
[*1]
not enter them.
12 15 Nm {1.2 1.5 kgm}
20 25 Nm {2.0 2.5 kgm}
30 35 Nm {3.0 3.5 kgm}

5
CPW11631

50-700
29
SEN03956-00

2008 KOMATSU
All Rights Reserved
50-700
30
SEN03957-00
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up
50

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
50-800

Removal and installation of monitor panel
SEN03957-00

monitor panel
3.
Remove 8 mounting bolts (1a) and panel cover

(1).
[*1]
4.
Remove 2 pieces (9) and 1 piece (10) of the

monitor panel mounting bolts.
[*2]
Removal
k
1.
2.

rear frames.
Pull out each switch from panel cover (1) on
the left side of the operator's seat and disconnect the following connectors.
q
(2): CN-L10
q
(3): CN-L11
q
(4): CN-L09
a The installed connectors and switches
depend on the specification.
Pull out each switch from panel cover (1) on

the right side of the operator's seat and disconnect 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

Removal and installation of monitor panel
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).
SEN03957-00
Installation
q

removal.
[*1]
Panel cover mounting bolt (1a):

3.44 4.40 Nm {0.35 0.45 kgm}
[*2]
7.
Monitor panel mounting bolts (9) and (10):

2.75 3.53 Nm {0.28 0.30 kgm}
Remove bracket (20) from monitor panel

assembly (11).
50-800

Removal and installation of engine controller assembly
SEN03957-00

engine controller assembly
4.
1
Removal
k
1.
Disconnect 5 mounting bolts (6) and engine

controller assembly (7).
[*2]
a Take care not to drop the engine controller
assembly or give it a shock.

rear frames.
Installation
q

removal.
Before installing the engine controller assembly, remove foreign matter (water, dirt, etc.)
from its wiring harness connector.
[*1]
2.
3.
Remove 2 connector mounting bolts (2). [*1]

a Width across flats of hexagonal socket of
mounting bolt: 4 mm
Disconnect connectors CN-EC2 (3), CN-EC1
(4) and CN-EC3 (5).
50-800
Wiring harness connector mounting bolt:

3 0.1 Nm {0.31 0.01 kgm}
[*2]
Engine controller assembly mounting bolt:

24 4 Nm {2.45 0.4 kgm}

Removal and installation of HST controller assembly

controller assembly
SEN03957-00
Installation
1
Removal
k

rear frames.
1.
Slide the operator's seat to the forward end.
2.
Remove cover (1) from the rear of the operator'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.

removal.
Before installing the HST controller assembly,
remove foreign matter (water, dirt, etc.) from its
wiring harness connector.
50-800

Removal and installation of KOMTRAX terminal assembly
SEN03957-00

KOMTRAX terminal assembly
4.
Disconnect wiring harness connector CN-L80

(3) on the chassis from KOMTRAX terminal
assembly (2).
a First, disconnect the wiring harness connector on the chassis then the antenna
cable connector because disconnecting
the antenna cable connector before disconnecting the wiring harness connector
input disconnection of the antenna cable
into the KOMTRAX.
[*1]
a To remove CN-L80 (3), loosen the hexagon socket head screw at its center. [*2]
5.
Disconnect antenna cable connectors (4) and

(5) from KOMTRAX terminal assembly (2).
Removal
k

rear frames.
1.
Open the right door of the operator's cab.

a Lock the door securely.
2.
Remove right armrest outside cover (1) of the

operator's seat.
3.
Remove KOMTRAX terminal assembly (2).
Installation
q

removal.
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 chassis.
[*2]
50-800
Hexagon socket head screw at center of wiring harness connector CN-L80 (3):
2.82 Nm {0.288 kgm}

Removal and installation of KOMTRAX terminal assembly
SEN03957-00
50-800
SEN03957-00

2008 KOMATSU
All Rights Reserved
50-800
SEN03958-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up

Automatic greasing circuit diagram................................................................................................................. 2
Hydraulic circuit diagram................................................................................................................................. 5
90-100
SEN03958-01
Automatic greasing circuit diagram

(If equipped)
90-100

SEN03958-01
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)
90-100
SEN03958-01
90-100

Hydraulic circuit diagram

WA320-6
WA320-6
a This figure covers the equipment and devices that are unavailable as optional items in some areas.
SEN03958-01
90-100
WA320PZ-6

WA320PZ-6
SEN03958-01
90-100
SEN03958-01
90-100
SEN03958-01

2009 KOMATSU
All Rights Reserved
90-100
10
SEN03959-01
WHEEL LOADER
WA320-6
WA320PZ-6
(KA SPEC.)
1SHOP MANUAL
Machine model
WA320-6
WA320PZ-6
(KA SPEC.)
Serial number
70001 and up
70001 and up

Electrical circuit diagram ................................................................................................................................. 3
Connector list and stereogram...................................................................................................................... 29
90-200
SEN03959-01
90-200
Common electrical circuit diagram (1/9)
Electrical circuit diagram
WA150-6, WA200-6, WA250-6, WA250PZ-6, WA320-6, WA320PZ-6


WA150-6, WA200-6, WA250-6, WA250PZ-6,
WA320-6, WA320PZ-6
SEN03959-01
90-200


WA150-6, WA200-6, WA250-6, WA250PZ-6,
WA320-6, WA320PZ-6
SEN03959-01
90-200


WA150-6, WA200-6, WA250-6, WA250PZ-6,
WA320-6, WA320PZ-6
SEN03959-01
90-200


WA150-6, WA200-6, WA250-6, WA250PZ-6,
WA320-6, WA320PZ-6
SEN03959-01
90-200

WA200-6, WA250-6, WA250PZ-6

WA200-6, WA250-6, WA250PZ-6
SEN03959-01
90-200
11


WA150-6, WA200-6, WA250-6, WA250PZ-6,
WA320-6, WA320PZ-6
SEN03959-01
90-200
13

WA200-6, WA250-6, WA250PZ-6

WA200-6, WA250-6, WA250PZ-6
SEN03959-01
90-200
15


WA150-6, WA200-6, WA250-6, WA250PZ-6,
WA320-6, WA320PZ-6
SEN03959-01
90-200
17


WA150-6, WA200-6, WA250-6, WA250PZ-6,
WA320-6, WA320PZ-6
SEN03959-01
90-200
19
Specific electrical circuit diagram (1/4)

WA320-6, WA320PZ-6

WA320-6, WA320PZ-6
SEN03959-01
90-200
21

WA320-6, WA320PZ-6

WA320-6, WA320PZ-6
SEN03959-01
90-200
23

WA320-6, WA320PZ-6

WA320-6, WA320PZ-6
SEN03959-01
90-200
25

WA320PZ-6

WA320PZ-6
SEN03959-01
90-200
27
Connector list and stereogram
Connector list and stereogram

WA320-6, WA320PZ-6 (KA SPEC.)
WA320-6, WA320PZ-6 (KA SPEC.)
Connector No.
Model
Number
of pins
Water in fuel sensor
Component name
Address of
stereogram
Connector No.
Model
Number
of pins
Diode
F-1
L70
SWP
Speed range select resistor
O-9
GND (front frame)
E-1
L71
DT-T
Intermediate connector
W-2
DT-T
Steering pump pressure switch
H-1
L79
KOMTRAX engine cut relay
P-6
Connector No.
Model
Number
of pins
F07A
DT-T
T-1
F10
Terminal
AC-3
F11
Address of
stereogram
Component name
Component name
Address of
stereogram
AL1
DT-T
AMBAIR
PRESURE
B01
DT-T
Rear work lamp RH
K-9
F12
DT-T
Emergency steering pressure switch
H-1
L80
DRC key A
40
KOMTRAX controller
T-8
B02
DT-T
Rear work lamp LH
M-8
F14
DT-T
Brake oil temperature switch
A-1
L100
Terminal
GND (floor)
Y-3
B03
DT-T
Back up alarm
M-7
F15
DT-T
Lift arm angle sensor (for load meter)
A-4
L101
FR press select relay
AB-7
B05
DT-T
Coolant level sensor
K-9
F16
DT-T
Lift arm bottom sensor (for load meter)
A-2
L102
VIS power hold relay
Z-8
B05
Terminal
GND (license lamp)
M-7
F17
DT-T
Lift arm rod sensor (for load meter)
E-1
L103
Motor 2 solenoid relay
Z-8
B06
08027
(R) Window sealed washer motor
I-9
FL1
DT-T
12
D-7, V-1
L104
Z-8
B07
08027
(F) Window sealed washer motor
I-9
FL2
DT-T
D-8, V-2
L105
Electrical parking brake relay
AA-7
B08
DT-T
Diode
K-9
FL3
DT-T
I-1, W-2
L106
Neutral safety relay
AA-7
B09
DT-T
Diode
J-9
FL4
DT-T
I-1, V-2
L107
Engine controller cut 1 relay
Z-7
Z-8
BL1
DT-T
X-2
FLC
DT-T
Front combination lamp RH
B-6
L108
Engine controller cut 2 relay
BOOST PRESS &

INT
Boost pressure sensor
AF-4
FLC1
DT-T
Front combination lamp LH
H-1
L109
Back alarm/lamp 1 relay
AB-7
BR1
DT-T
L-8
FLH
DT-T
Head lamp RH
B-6
L110
ECSS relay
AB-7
C04
DT
Front work lamp (RH) 24V/70W
E-8
FLH
DT-T
Head lamp LH
G-1
L111
HST solenoid safety relay
AB-8
C05
DT
Front work lamp (LH) 24V/70W
H-9
FS1
15
Fuse box
V-9
L112
Air clearner clog relay
AB-8
C07
Room lamp
H-9
FS2
15
Fuse box
V-9
L113
Boom kick out relay
AB-9
AG-5
L114
Bucket leveler relay
AA-9
C09
YAZAKI
7123-2228
YAZAKI
-08056
YAZAKI
-08056
C10
Door switch (LH) (room lamp)
H-9
FUEL RAIL
PRESS
Door switch (RH) (room lamp)
E-8
HEAD L
DT-T
G-1
L115
Detent active relay
AA-9
Terminal
GND to radio body
F-9
HEAD R
DT-T
A-5
L116
Horn relay
AA-9
C11
YAZAKI PA
AM/FM radio
F-9
HST
DRC
40
HST controller
Z-6
L117
Small lamp relay LH
AA-6
C12
Speaker LH
I-9
INJ. CYL. 1 & 2
Injector #1 & #2
AE-4
L118
Small lamp relay RH
AA-5
C13
Speaker RH
G-9
INJ. CYL. 3 & 4
Injector #3 & #4
AF-5
L119
Head lamp relay RH
AA-5
C14
198-Z11-2650
Lighter
D-7
INJ. CYL. 5 & 6
Injector #5 & #6
AG-5
L120
Head lamp relay LH
AA-5
C15
DT
J01
M6409-0075
20
Joint connector
R-6
L121
Stop lamp relay
C16
DT
Warning lamp (beacon)
J02
M6409-0255
20
Joint connector
R-6
L122
Front work lamp relay
AA-4
C17
SWP
Warning lamp (beacon) switch (If equipped)
J03
M6409-0071
20
Joint connector
V-1
L123
Rear work lamp relay
AB-4
C18
SWP
Warning lamp (pat. light) switch (If equipped)
J04
M6409-0075
20
Joint connector
Y-9
L124
Hazard/turn signal relay
AB-4
C18
Terminal
GND (cabin)
E-8
J05
M6409-0072
20
Joint connector
Y-9
L125
Hazard relay
AB-4
C19
SWP
Rear glass heater switch
G-9
J06
M6409-0071
20
Joint connector
Y-9
L126
Back alarm/lamp 2 relay
AB-6
C20
Relay for rear glass heater
G-9
J07
M6409-0072
20
Joint connector
R-8
L151
Front work lamp (yellow) relay (If equipped)
C21
Rear glass heater
G-9
J08
M6409-0075
20
Joint connector
Q-4
L152
Warning lamp (beacon) relay
C22
YAZAKI
7116-2270
YAZAKI
7116-2270
Rear glass heater
J-9
J09
M6440-0128
20
Joint connector
Y-9
L153
Warning lamp (pat.light) relay (If equipped)
C23
DT
E-8
J10
M6409-0255
20
Joint connector
Y-9
L154
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
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
N-3, AB-2
C49
DT-T
12
F-1
J13
M6409-0128
20
Joint connector
R-6
LR3
DT-T
N-3, AB-1
C50
DT-T
12
F-1
J14
M6409-0075
20
Joint connector
Z-8
LR4
#8
N-2, AB-1
C140
DRC
40
Tachograph controller
J15
M6440-0128
20
Joint connector
O-4
LR6
#8
M-3, X-1
C142
YAZAKI
7119-3170
17
Tachograph
J16
M6409-0128
20
Joint connector
Z-7
LR7
DT-T
12
M-3, X-1
CAM SENSOR
G sensor
AD-1
J17
M6409-0073
20
Joint connector
Z-7
LR10
DT-T
N-3, AB-2
CAN1
DT-T
CAN resistor
AG-1
L02
DT-T
Starting switch
R-9
LR11
DTP
M-3, X-1
CAN2
DT-T
CAN resistor
S-1
L03
DT-T
Speed range selector switch
R-8
LR12
#8
N-3, AB-1
CHK0
KOMTRAX inspection connector
P-6
L04
SWP
Combination lamp switch
T-1
LT1
DT-T
12
M-3, X-2
CHK1
KOMTRAX inspection connector
P-6
L05
10
Wiper switch (front, rear)
S-1
LT2
DT-T
M-3, X-2
CL1
SWP
C-6, O-2
L06
SWP
Hazard switch
R-6
MF1
DTM
12
Multi function lever switch
Engine pressure switch (low)
C08
Z-5
L07
SWP
Front work lamp switch
Q-5
OIL PRESURE
SWITCH
Diode
L08
SWP
Rear work lamp switch
R-6
PD1
DT-T
Throttle pedal switch
O-2
Diode
L09
SWP
ECSS switch
T-1
PD2
DT-T
Throttle pedal switch
O-2
Engine coolant temperature sensor
AD-4
L10
SWP
Monitor 1 switch
U-1
R00
Terminal
GND
M-8
IMA fuel pump actuator
AH-4
L11
SWP
Monitor 2 switch
T-1
R01
Terminal
Battery relay
A-8
CRANK SENSOR
Ne sensor
AD-1
L13
DT-T
Horn switch
T-1
R02
Terminal
Slow blow fuse
A-9
D01
SWP
Diode
O-8
L15
DT-T
FNR switch
S-2
R03
Terminal
Slow blow fuse
B-9
D02
SWP
Diode
O-8
L16
SWP
Loadmeter A/B (If equipped)
U-1
R04
Terminal
Battery relay
A-9
D03
SWP
Diode
O-8
L17
SWP
Loadmeter total (If equipped)
V-1
R05
Terminal
Slow blow fuse
B-9
D07
DT-T
Diode
O-7
L24
AMP 070
20
Monitor panel
R-2
R05A
Terminal
Slow blow fuse
B-9
D08
DT-T
Diode
O-7
L25
AMP 070
18
Monitor panel
R-2
R06
Terminal
Slow blow fuse
B-9
D09
DT-T
Diode
O-7
L26
AMP 070
12
Monitor panel
R-2
R11
Terminal
Slow blow fuse
B-9
D10
DT-T
Diode
O-7
L27
AMP 070
18
Monitor panel
Q-3
R15
Terminal
Battery relay
B-7
D21
DT-T
Diode
K-2
L28
AMP 070
12
Monitor panel
Q-4
R16
Terminal
Battery relay
A-7
D22
DT-T
Diode
J-1
L29
AMP 070
12
Monitor panel
T-7
R20
Terminal
GND (rear frame)
J-1
E01
DT-T
AF-5
L30
AMP 070
14
Monitor panel
S-7
R21
DT-T
Fuel level sensor
M-5
E02
SUMITOMO
6189-0442
Alternator
M-6
L34
DT-T
Stop lamp switch
W-2
R22
DT-T
Rear combination lamp LH
M-6
E03
Terminal
Alternator terminal B
M-7
L35
DT
PPC valve with electrical detent
Q-9
R23
DT-T
Rear combination lamp RH
K-9
E05
Terminal
Heater relay terminal B
C-7
L36
DT
R-6
R24
DT-T
License lamp (If equipped)
L-9
E06
Terminal
Heater relay
C-9
L37
DT
R-6
R26
Terminal
GND (rear frame)
G-1
E06A
DT-T
Diode
K-2
L38
DT-T
UN switch +24 V (If equipped)
Z-4
R29
DT-T
Oil fan EPC solenoid
L-9
E07A
Terminal
Heater relay terminal A
AF-5
L39
DT-T
Key on +24 V (If equipped)
Z-4
R59
DT-T
M-8
E07B
Electrical intake air heater
AD-9
L45
DT-T
Auto lubrication
AB-2
R90
Terminal
Heater relay terminal E
L-4
E10
DT-T
Freon compressor magnet clutch
AH-1
L46
Buzzer
W-9
SV
DT-T
12
Service connector
Y-8
E14
Terminal
GND (engine controller)
AG-1
L47
DT
Parking brake indicator switch
Y-3
T01
DT-T
HST pump solenoid
AC-4
E15
Terminal
GND (engine controller)
AH-1
L48
08027
Wiper timer
X-2
T01A
Diode
AD-4
E19
Terminal
AG-6
L49
08027
Flasher
AA-3
T01B
Diode
AD-4
E20
Terminal
AG-6
L50
DT-T
12
Z-6
T05
DT-T
Clutch control EPC solenoid
N-2, AN-7
E21
Terminal
Starting motor terminal C
AC-7
L52
Rear wiper motor
X-9
T06
DT-T
HST motor 1 EPC solenoid
L-1, AK-2
E26
DT-T
Engine oil level sensor
AF-5
L53
DT
Parking brake remind switch
Z-5
T07
DT-T
HST motor 2 solenoid & motor 2 overrun solenoid
L-2, AJ-7
E30
Terminal
Starting motor terminal B
AE-4
L54
DT-T
Variable shift control switch
T-8
T09
DT-T
Speed sensor
L-2, AL-8
E33
DT-T
Dust indicator
J-9
L55
DT
Air suspension seat
Z-5
T10
DT-T
L-2, AK-8
E41
DT-T
AF-1
L57
Front wiper motor
Q-3
T11
DT-T
M-1, AL-3
E42
DT-T
AH-2
L58
12V option converter output
Z-4
T12
DT-T
Brake accumurator pressure switch
I-1
EC1
DRC
60
Engine controller module
AE-1
L59
DT-T
Bucket lever LDM cancel switch (If equipped)
Q-6
T13
HST filter clogging sensor
M-1
EC2
DRC
50
AD-2
L60
DT-T
Z-4
T14
Terminal
GND
M-1
EC3
DTP
AF-1
L61
DT-T
Boom lever TCS cancel switch
Q-6
T15
DT-T
Parking brake solenoid
ER1
DT-T
12
D-8, AE-5
L62
DT-T
Q-6
T15A
DT-T
Diode
ER2
DT-T
12
D-8, AE-5
L63
SWP
FNR active switch
Q-9
T18
DT-T
Parking brake pressure switch (for monitor indicator)
ER3
DT-T
D-8, AE-5
L64
SWP
Traction switch
Q-9
T31
DT-T
Diode
F01
08160-70001
Horn (high)
C-1
L65
SWP
Work lamp (yellow) (If equipped)
R-6
T32
DT-T
Diode
F02
08160-70001
Horn (low)
D-1
L66
O-3
TEL
DT-T
12
F03
DT-T
Bucket positioner proximity switch
A-3
L67
DT-T
12
W-9
TOOL PORT
CAN resistor
F04
DT-T
Lift arm positioner proximity switch
A-4
L68
DT-T
Resistor
O-7
Z01
DT-T
Diode
F07
DT-T
ECSS solenoid valve
F-1
L69
SWP
Auto reversible fan switch
Q-9
Z02
DT-T
Diode
CL2
SWP
CL31
DT-T
CL32
DT-T
COOLANT TEMP
CP3 PUMP
REGULATOR
C-7, O-3
AH-2
L-2, AL-8
N-1
N-2, AN-7
P-6
AD-2
SEN03959-01
90-200
29
SEN03959-01
90-200
31
SEN03959-01

2009 KOMATSU
All Rights Reserved
90-200
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WA 320-6 Shop Manual

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WA 320-6 Shop Manual

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SEN03911-02

00 Index and foreword

WA320, 320PZ-6 (KA SPEC.)

Composition of shop manual

WA320, 320PZ-6 (KA SPEC.)

Troubleshooting by failure code (Display of code), Part 5..................................................SEN03943-01

50 Disassembly and assembly ........................................................................................................SEN03918-02

WA320, 320PZ-6 (KA SPEC.)

00 Index and foreword

WA320, 320PZ-6 (KA SPEC.)

400 Brake system

WA320, 320PZ-6 (KA SPEC.)

30 Testing and adjusting

WA320, 320PZ-6 (KA SPEC.)

WA320, 320PZ-6 (KA SPEC.)

Failure code [CA352] Sensor power supply 1 low error................................................................................ 52

WA320, 320PZ-6 (KA SPEC.)

WA320, 320PZ-6 (KA SPEC.)

50 Disassembly and assembly

WA320, 320PZ-6 (KA SPEC.)

90 Diagrams and drawings

WA320, 320PZ-6 (KA SPEC.)

WA320, 320PZ-6 (KA SPEC.)

WA320-6, WA320PZ-6 (KA SPEC.) Wheel loader

00 Index and foreword

200 Foreword and general information

WA320, 320PZ-6 (KA SPEC.)

200 Foreword and general information

Important safety notice

If welding repairs are needed, always

Prohibition of operation and handling by

6 Safety check before starting work

Wearing protective goggles

Wearing shielding goggles and protectors

9 Good physical condition and preparation

Precautions against work which you are

WA320, 320PZ-6 (KA SPEC.)

200 Foreword and general information

Preparations for work

Precautions during work

WA320, 320PZ-6 (KA SPEC.)

When removing a cover which is under

200 Foreword and general information

Precautions for sling work and making

When installing wire ropes to an angular

11) Do not use twisted or kinked wire ropes.

WA320, 320PZ-6 (KA SPEC.)

200 Foreword and general information

If the load is unstable or the wire rope

Precautions for using mobile crane

WA320, 320PZ-6 (KA SPEC.)

Selecting wire ropes

The allowable load is one-sixth of the

200 Foreword and general information

Example of O-ring (Fitted to every joint of

For tightening torque, see the precautions for

WA320, 320PZ-6 (KA SPEC.)

200 Foreword and general information

How to read the shop manual

Composition of shop manual

Revision and distribution

WA320, 320PZ-6 (KA SPEC.)

200 Foreword and general information

Revised edition mark