Professional Documents
Culture Documents
(E MODE)
WA320-5H 20-601
TESTING AND ADJUSTING BEFORE TROUBLESHOOTING ELECTRICAL SYSTEM
a This connection chart shows the equipment that each fuse box power source supplies power directly to
("switch power source" means the power supplied when the starting switch is ON; "permanent power source"
means the power supplied when the starting switch is OFF).
20-602 WA320-5H
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBULESHOOTING TABLE
Effect on • Condition that appeared as problem on machine when action (given above) was taken by machine monitor or control-
Machine ler.
WA320-5H 20-603
TESTING AND ADJUSTING INFORMATION CONTAINED IN TROUBULESHOOTING TABLE
This is part of electrical circuit diagram which shows the portion where the failure occurred.
• Connector No.: Indicates (Type - numbers of a pin) (color)
• Arrow: Roughly indicates the location in the machine where it is installed.
20-604 WA320-5H
white 20-605
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
20-606 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
WA320-5H 20-607
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
20-608 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
Controller
Action Code Failure Code The engine does not start
Code Trouble
a) Defective starting motor system
- - -
Description of • The engine does not start due to defective starting motor system.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • The engine does not start.
Machine
• If the failure code D5ZHL6 for abnormality in starting switch C input is given, carry out troubleshooting first for the
applicable code.
Related • If the fuses are blown, check the wiring harness is short-circuited with the ground.
Information
• When the directional selector actuation switch is operated, the directional lever must be in the "N" position and the
directional selector switch must be in the "N" position.
WA320-5H 20-609
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
20-610 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
WA320-5H 20-611
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
20-612 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
WA320-5H 20-613
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
20-614 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
Controller
Action Code Failure Code The engine does not start
Code Trouble
a) Defective starting motor system
- - -
Description of • The engine does not start due to defective starting motor system.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • The engine does not start.
Machine
• If the failure code D5ZHL6 for abnormality in starting switch C input is given, carry out troubleshooting first for the
applicable code.
Related • If the fuses are blown, check the wiring harness is short-circuited with the ground.
Information
• When the directional selector actuation switch is operated, the directional lever must be in the "N" position and the
directional selector switch must be in the "N" position.
WA320-5H 20-615
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
20-616 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-1]
WA320-5H 20-617
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-2]
Related • If the failure code D5ZHL6 for abnormality in starting switch C input is given, carry out troubleshooting first for the
Information applicable code.
Hot short-circuiting Wiring harness between E03, Voltage between E03 (Harness 1V and below
3 R09 and D03 (Female) (1) side) and chassis ground
between harnesses
Wiring harness between E23,
Voltage between E23 (Harness
L02 (Female) (4) and R08 side) and chassis ground 1V and below
(Female) (1)
20-618 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-2]
WA320-5H 20-619
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-2]
20-620 WA320-5H
white 20-621
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]
Defective intake air heater 1) Turn starting switch OFF. 2) Disconnect heater terminal E09. 3) Solid part check.
2
(Ribbon heater) Between heater terminal E09 and chassis ground Resistance 0.17 - 0.27z
1) Turn starting switch OFF. 2)Replace relay L115 with normal relay 3) Turn starting
switch ON.
Condition is Relay L115 is
Does condition become normal when automatic abnormal. normal.
preheating relay L115 is replaced with normal
relay? Condition is Defective
normal. relay L115.
Defective auto-preheating 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
Possible 3
Causes and relay (L115) Between L115 (Male) (1) and (2) Resistance 200 - 400z
Standard
Values 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
4) Applies impressed voltage between L115 (Male) (1) - (2)
Applies 24V impressed voltage
Between Resistance 1zandbelow
between L115 (Male) (1) - (2)
L115 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L115 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Replace diode (D05) with normal diode. 3) Turn start-
ing switch ON.
Condition is abnormal. Diode (D05) is normal.
Condition is normal. Defective diode (D05)
Measure between (2) o (1) with diode range Continuity
Measure between (2) o (3) with diode range Continuity
Measure between (1) o (2) with diode range
4 Defective diode (D05)
No continuity
Measure between (1) o (3) with diode range No continuity
Measure between (3) o (2) with diode range No continuity
Measure between (3) o (1) with diode range No continuity
a Put (+) pole of tester in contact with left side.
20-622 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]
Wiring harness discontinu- Wiring harness between E06, J08 and L115 Resistance 1zandbelow
(Female) (5)
5 ity (Disconnection or defec-
tive contact) Wiring harness between fuse FS2 (5) and L115
Resistance 1zandbelow
(Female) (3)
Wiring harness between fuse FS2 (5) and L115
Resistance 1zandbelow
(Female) (1)
Wiring harness between L115 (Female) (2) and Resistance 1zandbelow
L22 (Female) (4)
1) Turn starting switch OFF. 2) Disconnect connector D05, L115, L22, fuse FS2 (5),
E06, E07 E08, E09 and R07. 3) Connect T-adapter.
Wiring harness between E08 Resistance between E08, E09 1Mz and
and E09 * and chassis ground above
Wiring harness between R07 Resistance between R07, E07 1Mz and
and E07 * and chassis ground above
Resistance between E06, J08,
Wiring harness between E06, 1Mz and
J08 and L115 (Female) (5) * L115 (Female) (5) and chassis above
ground
Possible
Causes and Wiring harness between fuse Resistance between fuse FS2
Standard FS2 (5) and L115 (Female) (5), L115 (Female) (3) and 1Mz and
above
Values (3) * chassis ground
6 Wiring harness ground fault Wiring harness between fuse Resistance between fuse FS2
FS2 (5) and L115 (Female) 1Mz and
(5), L115 (Female) (1) and above
(1) * chassis ground
Wiring harness between J08 Resistance between J08
(Female) (12) and D05 (Female) (12), D05 (Female) 1Mz and
above
(Female) (3) * (3) and chassis ground
a Item 6 above is wiring harness related to intake air heater (ribbon heater)
a If it is marked * , the fuse is blown
WA320-5H 20-623
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]
b) Preheating is constant
Controller
Action Code Failure Code Preheating is impossible or constant
Code Trouble
b) Preheating is constant
- - -
Description of • Preheating is constant.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Preheating is constant.
Machine
• If the failure code DGE3L6 for abnormality in engine water temperature (low temperature) sensor related is given,
Related carry out troubleshooting first for the applicable code.
Information
• The engine water temperature (low temperature) is displayed by real-time monitoring code 04103.
Defective auto-preheating 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
2
relay (L115) Between L115 (Male) (1) and (2) Resistance 200 - 400z
Possible 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
Causes and 4) Applies impressed voltage between L115 (Male) (1) - (2)
Standard
Values Applies 24V impressed voltage Resistance 1zandbelow
Between between L115 (Male) (1) - (2)
L115 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L115 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Disconnect connector L115, L22, fuse FS2 (5), E06,
E07 and E08. 3) Connect T-adapter. 4) 1 minute after starting switch is turned ON.
Hot short-circuiting Wiring harness between E08 Voltage between E08, E09 and
3 1V and below
and E09 chassis ground
between harnesses
Wiring harness between E06, Voltage between E06, J08,
L115 (Female) (5) and chassis 1V and below
J06 and L115 (Female) (5)
ground
1) Turn starting switch OFF. 2) Disconnect connectors L22 and L115.
3) Connect T-adapter.
Short circuit with chassis
4 Wiring harness between L22 Resistance between L22
ground in wiring harness 1Mz and
(female) (4) and L115 (female) (female) (4), L115 (female) (2)
above
(2) and chassis ground
1) Turn starting switch OFF. 2) Disconnect connector L22. 3) Insert T-adapter.
Defective mechanical mon- 4) Connect connector. 5) 1 minute after starting switch is turned ON.
5
itor 16 V and
Voltage between L22 (4) and chassis ground
above
20-624 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]
WA320-5H 20-625
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]
Defective intake air heater 1) Turn starting switch OFF. 2) Disconnect heater terminal E09. 3) Solid part check.
2 (Ribbon heater) Between heater terminal E09 and chassis ground Resistance 0.17 - 0.27z
1) Turn starting switch OFF. 2)Replace relay L115 with normal relay 3) Turn starting
switch ON.
Condition is Relay L115 is
Does condition become normal when automatic abnormal. normal.
preheating relay L115 is replaced with normal
relay? Condition is Defective
normal. relay L115.
Defective auto-preheating 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
Possible 3
Causes and relay (L115) Between L115 (Male) (1) and (2) Resistance 200 - 400z
Standard
Values 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
4) Applies impressed voltage between L115 (Male) (1) - (2)
Applies 24V impressed voltage
Between between L115 (Male) (1) - (2) Resistance 1zandbelow
L115 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L115 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Replace diode (D05) with normal diode. 3) Turn start-
ing switch ON.
Condition is abnormal. Diode (D05) is normal.
Condition is normal. Defective diode (D05)
Measure between (2) o (1) with diode range Continuity
Measure between (2) o (3) with diode range Continuity
Measure between (1) o (2) with diode range
4 Defective diode (D05)
No continuity
Measure between (1) o (3) with diode range No continuity
Measure between (3) o (2) with diode range No continuity
Measure between (3) o (1) with diode range No continuity
a Put (+) pole of tester in contact with left side.
20-626 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]
Wiring harness discontinu- Wiring harness between E06, J08 and L115 Resistance 1zandbelow
(Female) (5)
5 ity (Disconnection or defec-
tive contact) Wiring harness between fuse FS2 (5) and L115
Resistance 1zandbelow
(Female) (3)
Wiring harness between fuse FS2 (5) and L115
Resistance 1zandbelow
(Female) (1)
Wiring harness between L115 (Female) (2) and Resistance 1zandbelow
L24 (Female) (12)
1) Turn starting switch OFF. 2) Disconnect connector D05, L115, L28, fuse FS2 (5),
E06, E07 E08, E09 and R07. 3) Connect T-adapter.
Wiring harness between E08 Resistance between E08, E09 1Mz and
and E09 * and chassis ground above
Wiring harness between R07 Resistance between R07, E07 1Mz and
and E07 * and chassis ground above
Resistance between E06, J08,
Wiring harness between E06, 1Mz and
J08 and L115 (Female) (5) * L115 (Female) (5) and chassis above
ground
Possible
Causes and Wiring harness between fuse Resistance between fuse FS2
Standard FS2 (5) and L115 (Female) (5), L115 (Female) (3) and 1Mz and
above
Values (3) * chassis ground
6 Wiring harness ground fault Wiring harness between fuse Resistance between fuse FS2
FS2 (5) and L115 (Female) 1Mz and
(5), L115 (Female) (1) and above
(1) * chassis ground
Wiring harness between J08 Resistance between J08
(Female) (12) and D05 (Female) (12), D05 (Female) 1Mz and
above
(Female) (3) * (3) and chassis ground
a Item 6 above is wiring harness related to intake air heater (ribbon heater)
a If it is marked * , the fuse is blown
WA320-5H 20-627
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]
b) Preheating is constant
Controller
Action Code Failure Code Preheating is impossible or constant
Code Trouble
b) Preheating is constant
- - -
Description of • Preheating is constant.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Preheating is constant.
Machine
• If the failure code DGE3L6 for abnormality in engine water temperature (low temperature) sensor related is given,
Related carry out troubleshooting first for the applicable code.
Information
• The engine water temperature (low temperature) is displayed by real-time monitoring code 04103.
Defective auto-preheating 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
2
relay (L115) Between L115 (Male) (1) and (2) Resistance 200 - 400z
Possible 1) Turn starting switch OFF. 2) Disconnect connector L115. 3) Solid part check.
Causes and 4) Applies impressed voltage between L115 (Male) (1) - (2)
Standard
Values Applies 24V impressed voltage Resistance 1zandbelow
Between between L115 (Male) (1) - (2)
L115 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L115 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Disconnect connector L115, L24, fuse FS2 (5), E06,
E07 and E08. 3) Connect T-adapter. 4) 1 minute after starting switch is turned ON.
Hot short-circuiting Wiring harness between E08 Voltage between E08, E09 and
3 1V and below
and E09 chassis ground
between harnesses
Wiring harness between E06, Voltage between E06, J08,
L115 (Female) (5) and chassis 1V and below
J06 and L115 (Female) (5)
ground
1) Turn starting switch OFF. 2) Disconnect connectors L24 and L115.
3) Connect T-adapter.
Short circuit with chassis
4 Wiring harness between L24 Resistance between L24
ground in wiring harness 1Mz and
(female) (12) and L115 (female) (female) (12), L115 (female) (2)
above
(2) and chassis ground
1) Turn starting switch OFF. 2) Disconnect connector L24. 3) Insert T-adapter.
Defective mechanical mon- 4) Connect connector. 5) 1 minute after starting switch is turned ON.
5
itor 16 V and
Voltage between L24 (12) and chassis ground
above
20-628 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-3]
WA320-5H 20-629
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
Defective parking brake 1) Turn starting switch OFF. 2) Disconnect connector L112. 3) Solid part check.
1 neutral safety relay (L112) Between L112 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L112. 3) Solid part check.
4) Applies impressed voltage between L112 (Male) (1) - (2)
Applies 24V impressed voltage
Between between L112 (Male) (1) - (2) Resistance 1zandbelow
L112 (Male)
(3) and (5) Does not apply voltage 1Mz and
between L112 (Male) (1) - (2) Resistance above
Possible 1) Turn starting switch OFF. 2) Disconnect connector D01, L19, L112, T01. 3) Con-
Causes and nect T-adapter.
Standard
Wiring harness between L112 Resistance between L112
Values 1Mz and
2 Wiring harness ground fault (Female) (5) and J08 (7), (9) (Female) (5), T01 (Female) (4) above
and T01 (Female) (2), (4) and chassis ground
Wiring harness between L112 Resistance between L112
1Mz and
(Female) (5) and J08 (7), (8) (Female) (5), T01 (Female) (2)
above
and T01 (Female) (2) and chassis ground
1) Turn starting switch OFF. 2) Replace diode D01 with normal diode. 3) Turn start-
ing switch ON.
Condition is abnormal. Diode (D05) is normal.
Condition is normal. Defective diode (D01)
Measure between (2) o (1) with diode range Continuity
Measure between (2) o (3) with diode range
3 Defective diode (D01)
Continuity
Measure between (1) o (2) with diode range Discontinuity
Measure between (1) o (3) with diode range Discontinuity
Measure between (3) o (2) with diode range Discontinuity
Measure between (3) o (1) with diode range Discontinuity
20-630 WA320-5H
white 20-631
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
Defective mechanical type 1) Turn starting switch OFF. 2) Disconnect connector L101. 3) Solid part check.
3
parking brake relay (L101) Between L101 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L101. 3) Solid part check.
4) Applies impressed voltage between L101 (Male) (1) - (2)
Applies 24V impressed voltage Resistance 1zandbelow
Between between L101 (Male) (1) - (2)
L101 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L101 (Male) (1) - (2) above
20-632 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
6 Defective junction connec- • Carry out inspection, and if any abnormality is found, repair or replace.
tor (J05), (J10) and (J12)
1) Turn starting switch OFF. 2) Disconnect connector L21. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch
WA320-5H 20-633
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
20-634 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
WA320-5H 20-635
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
Defective parking brake 1) Turn starting switch OFF. 2) Disconnect connector L112. 3) Solid part check.
1
neutral safety relay (L112) Between L112 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L112. 3) Solid part check.
4) Applies impressed voltage between L112 (Male) (1) - (2)
Applies 24V impressed voltage
Between Resistance 1zandbelow
between L112 (Male) (1) - (2)
L112 (Male)
(3) and (5) Does not apply voltage 1Mz and
between L112 (Male) (1) - (2) Resistance above
Possible 1) Turn starting switch OFF. 2) Disconnect connector D01, L19, L112, T01. 3) Con-
Causes and nect T-adapter.
Standard
Values Wiring harness between L112 Resistance between L112 1Mz and
2 Wiring harness ground fault (Female) (5) and J08 (7), (9) (Female) (5), T01 (Female) (4) above
and T01 (Female) (2), (4) and chassis ground
Wiring harness between L112 Resistance between L112
1Mz and
(Female) (5) and J08 (7), (8) (Female) (5), T01 (Female) (2) above
and T01 (Female) (2) and chassis ground
1) Turn starting switch OFF. 2) Replace diode D01 with normal diode. 3) Turn start-
ing switch ON.
Condition is abnormal. Diode (D05) is normal.
Condition is normal. Defective diode (D01)
Measure between (2) o (1) with diode range Continuity
3 Defective diode (D01) Measure between (2) o (3) with diode range Continuity
Measure between (1) o (2) with diode range Discontinuity
Measure between (1) o (3) with diode range Discontinuity
Measure between (3) o (2) with diode range Discontinuity
Measure between (3) o (1) with diode range Discontinuity
20-636 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
Defective mechanical type 1) Turn starting switch OFF. 2) Disconnect connector L101. 3) Solid part check.
3
parking brake relay (L101) Between L101 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L101. 3) Solid part check.
4) Applies impressed voltage between L101 (Male) (1) - (2)
Applies 24V impressed voltage Resistance 1zandbelow
Between between L101 (Male) (1) - (2)
L101 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L101 (Male) (1) - (2) above
WA320-5H 20-637
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
Defective junction connec- • Carry out inspection, and if any abnormality is found, repair or replace.
6 tor (J05), (J10) and (J12)
1) Turn starting switch OFF. 2) Disconnect connector L25. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch
20-638 WA320-5H
white 20-639
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
20-640 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-4]
WA320-5H 20-641
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-5]
Description of • Boom kick-out does not function or cannot be cancelled due to defective boom kick-out proximity switch system, lift
Trouble arm PPC detent system and lift arm detent relay system.
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Boom kick-out does not function or cannot be cancelled.
Machine
Related
Information
Defective lift arm PPC 1) Turn starting switch OFF. 2) Disconnect connector L36. 3) Connect T-adapter.
2 detent Between L36 (Male) (1) and (2) Resistance 30 - 50z
1) Turn starting switch OFF. 2) Disconnect connector F04. 3) Interchange lift arm
positioner proximity switch (F04) with bucket positioner proximity switch (F03). 4)
Operate boom kick-out.
Possible
Causes and 3 Defective lift arm posi- Defective boom kick-out prox-
tioner proximity switch Boom kick-out function is normal.
Standard imity switch F04
Values
Boom kick-out proximity switch
Boom kick-out does not function.
F04 is normal.
1) Turn starting switch OFF. 2) Disconnect connector F04, L113, L36 and fuse FS1
terminal. 3) Connect T-adapter.
Wiring harness between F04 (Female) (A) and Resistance 1zandbelow
fuse FS1 (13)
Wiring harness between F04 (Female) (B) and
Resistance 1zandbelow
L113 (Female) (2)
Wiring harness between F04 (Female) (C) and
Resistance 1zandbelow
chassis ground
Wiring harness discontinu-
4 ity (Disconnection or defec- Wiring harness between L113 (Female) (1) and Resistance 1zandbelow
tive contact) fuse FS1 (13)
Wiring harness between L113 (Female) (3) and
Resistance 1zandbelow
fuse FS1 (13)
Wiring harness between L113 (Female) (5) and Resistance 1zandbelow
L36 (Female) (1)
Wiring harness between L36 (Female) (2) and
Resistance 1zandbelow
chassis ground
a With all the above items, the boom kick-out does not function
20-642 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-5]
a In this case, the fuse is blown and no detents function (lever returns to neutral)
WA320-5H 20-643
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-5]
20-644 WA320-5H
white 20-645
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-6]
Description of • Bucket positioner does not function or cannot be cancelled due to defective bucket positioner proximity switch system,
Trouble bucket PPC detent system and bucket detent relay system.
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Bucket positioner does not function or cannot be cancelled.
Machine
Related
Information
Defective bucket PPC 1) Turn starting switch OFF. 2) Disconnect connector L37. 3) Connect T-adapter.
2 detent Between L37 (Male) (1) and (2) Resistance 30 - 50z
1) Turn starting switch OFF. 2) Disconnect connector F03. 3) Interchange bucket
positioner proximity switch (F03) with lift arm positioner proximity switch (F04). 4)
Operate bucket positioner.
Possible
Causes and 3 Defective bucket posi- Defective bucket positioner
tioner proximity switch Bucket positioner function is normal.
Standard proximity switch F03
Values
Bucket positioner proximity
Bucket positioner does not function.
switch F03 is normal.
1) Turn starting switch OFF. 2) Disconnect connector F03, L114, L37 and fuse FS1
terminal. 3) Connect T-adapter.
Wiring harness between F03 (Female) (A) and Resistance 1zandbelow
fuse FS1 (13)
Wiring harness between F03 (Female) (B) and
Resistance 1zandbelow
L114 (Female) (2)
Wiring harness between F03 (Female) (C) and
Resistance 1zandbelow
chassis ground
Wiring harness discontinu-
4 ity (Disconnection or defec- Wiring harness between L114 (Female) (1) and Resistance 1zandbelow
tive contact) fuse FS1 (13)
Wiring harness between L114 (Female) (3) and
Resistance 1zandbelow
fuse FS1 (13)
Wiring harness between L114 (Female) (5) and Resistance 1zandbelow
L37 (Female) (1)
Wiring harness between L37 (Female) (2) and
Resistance 1zandbelow
chassis ground
a With all the above items, the bucket positioner does not function
20-646 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-6]
WA320-5H 20-647
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-6]
20-648 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-7]
Description of • Lift arm FLOATING holding does not function or cannot be cancelled due to defective lift arm FLOATING PPC detent
Trouble system.
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Lift arm FLOATING holding does not function or cannot be cancelled.
Machine
Related
Information
Defective lift arm FLOAT- 1) Turn starting switch OFF. 2) Disconnect connector L35. 3) Connect T-adapter.
1
ING PPC detent Between L35 (Male) (1) and (2) Resistance 30 - 50z
Possible
Causes and 1) Turn starting switch OFF. 2) Disconnect connector L35 and fuse FS1 terminal. 3)
Standard Connect T-adapter.
Values Wiring harness discontinu-
2 ity (Disconnection or defec- Wiring harness between fuse FS1 (13) and L35
Resistance 1zandbelow
(Female) (1)
tive contact)
Wiring harness between L35 (Female) (2) and Resistance 1zandbelow
chassis ground
WA320-5H 20-649
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]
0V OV o
Values
Between L48 (5) and chassis ground
(The voltage is output intermittently by wiper Voltage
20 - 30V
switch INT)
(Repeated)
1) Turn starting switch OFF. 2) Disconnect connector L05. 3) Insert T-adapter.
4) Connect connector. 5) Turn starting switch ON.
20-650 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]
WA320-5H 20-651
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]
20-652 WA320-5H
white 20-653
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]
Wiring harness between fuse FS1 (14) and L57 Resistance 1zandbelow
(Female) (6)
1) Turn starting switch OFF. 2) Disconnect connector L05, L48, L52, L57 and fuse
FS1 terminal. 3) Connect T-adapter.
Wiring harness between L05 Resistance between L05
(Female) (8) and L52 (Female) 1Mz and
(Female) (8), L52 (Female) (1)
(1) above
and chassis ground
Wiring harness between L05 Resistance between L05
(Female) (9) and L52 (Female) (Female) (9), L52 (Female) (2) 1Mz and
above
(2) and chassis ground
4 Wiring harness ground fault
Resistance between L05
Wiring harness between fuse 1Mz and
(Female) (7) and chassis
FS1 (14) and L05 (Female) (7) above
ground
Resistance between L52
Wiring harness between fuse 1Mz and
(Female) (6) and chassis
FS1 (14) and L52 (Female) (4) ground above
20-654 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-8]
WA320-5H 20-655
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-9]
Description of • The window washer does not function due defective window washer motor, switch, timer (Front only) or wiring har-
Trouble ness.
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • The window washer does not function.
Machine
Related
Information
20-656 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-9]
Possible 1) Turn starting switch OFF. 2) Disconnect connector L05, L48, L52, L57, D10, D13
Causes and and fuse FS1 terminal. 3) Connect T-adapter.
Standard
Values • Front side
WA320-5H 20-657
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-9]
20-658 WA320-5H
white 20-659
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
Description of • Head lamp (Hi beam and Lo beam) does not light ON due to defective switch, lamp or wiring harness (Ground fault) in
Trouble the head lamp system.
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Head lamp (Hi beam and Lo beam) does not light ON when the lamp switch is turned STEP 2.
Machine
• If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and relay,
Related between fuse and lamp)
Information
• When circuits for other lamp systems are normal
2 Defective lamp switch and Turn lamp switch STEP 2. Resistance 1zandbelow
dimmer switch
Between L04 Turn dimmer switch Lo. Resistance 1zandbelow
(Male) (4) and 1Mz and
(3) Turn dimmer switch Hi. Resistance
above
20-660 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
Defective head lamp relay 1) Turn starting switch OFF. 2) Disconnect connector L120. 3) Solid part check.
3 4) Applies impressed voltage between L120 (Male) (1) - (2)
(Left side) (L120)
Between L120 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L120. 3) Solid part check.
Applies 24V impressed voltage Resistance 1zandbelow
Between between L120 (Male) (1) - (2)
L120 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L120 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Replace relay L119 with normal relay. 3) Turn starting
switch ON.
Defective head lamp relay 1) Turn starting switch OFF. 2) Disconnect connector L119. 3) Solid part check.
4
(Right side) (L119) Between L119 (Male) (1) and (2) Resistance 200 - 400z
Possible 1) Turn starting switch OFF. 2) Disconnect connector L119. 3) Solid part check.
Causes and 4) Applies impressed voltage between L119 (Male) (1) - (2)
Standard
Values Applies 24V impressed voltage
Between Resistance 1zandbelow
between L119 (Male) (1) - (2)
L119 (Male)
(3) and (5) Does not apply voltage 1Mz and
Resistance
between L119 (Male) (1) - (2) above
1) Turn starting switch OFF. 2) Disconnect connector L04, L120, L119, HEAD L,
HEAD R and fuse FS1 terminal (8), (9). 3) Connect T-adapter.
a When both sides are defective (in this case, clearance lamp also does not light
up)
WA320-5H 20-661
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
9JF01508
20-662 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
9JF01509
WA320-5H 20-663
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
Description of • Head lamp (Lo beam) does not light ON due to defective switch, lamp or wiring harness (Ground fault) in the head
Trouble lamp system.
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Head lamp (Lo beam) does not light ON when the lamp switch is turned STEP 2.
Machine
Related • If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and lamp)
Information • When circuits for other lamp systems are normal
20-664 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
Description of • Head lamp (Hi beam) does not light ON due to defective switch, lamp or wiring harness (Ground fault) in the head
Trouble lamp system.
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Head lamp (Hi beam) does not light ON when the lamp switch is turned STEP 2.
Machine
Related • If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and lamp)
Information • When circuits for other lamp systems are normal
WA320-5H 20-665
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
Description of • Clearance lamp (Small lamp) does not light ON due to defective switch, lamp or wiring harness (Ground fault) in the
Trouble clearance lamp system.
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Clearance lamp (Small lamp) does not light ON when the lamp switch is turned STEP 1.
Machine
Related • If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and lamp)
Information • When circuits for other lamp systems are normal
20-666 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
WA320-5H 20-667
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
Description of • Turn signal lamp does not blink due to defective switch, lamp or wiring harness (Ground fault) in the turn signal lamp
Trouble system.
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Turn signal lamp does not blink
Machine
Related • If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and lamp)
Information • When circuits for other lamp systems are normal
20-668 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
WA320-5H 20-669
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
Description of • Working lamp does not light ON due to defective switch, lamp or wiring harness (Ground fault) in the clearance lamp
Trouble system.
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Working lamp does not light ON.
Machine
• If fuse is blown, there is short circuit with ground, so inspect applicable wiring harness (between fuse and lamp)
Related • When circuits for other lamp systems are normal
Information
• When side lamps do not light up, carry out troubleshooting first for side lamp system.
Defective working lamp 1) Turn starting switch OFF. 2) Disconnect connector L122. 3) Solid part check.
3
relay (L122) Between L122 (Male) (1) and (2) Resistance 200 - 400z
1) Turn starting switch OFF. 2) Disconnect connector L122. 3) Solid part check.
4) Applies impressed voltage between L122 (Male) (1) - (2)
Applies 24V impressed voltage Resistance 1zandbelow
Between between L122 (Male) (1) - (2)
L122 (Male)
(3) and (5) Does not apply voltage Resistance 1Mz and
between L122 (Male) (1) - (2) above
20-670 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-10]
WA320-5H 20-671
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]
20-672 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-11]
WA320-5H 20-673
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]
2
Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
control panel
20-674 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]
WA320-5H 20-675
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]
Controller
Action Code Failure Code Defective air conditioner
Code Trouble
b) Air does not flow out or amount of air cannot be adjusted.
- - -
Description of • Air does not flow out or amount of air cannot be adjusted.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Air does not flow out or amount of air cannot be adjusted.
Machine
Related
Information
20-676 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]
10
Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
control panel
WA320-5H 20-677
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]
Controller
Action Code Failure Code Defective air conditioner
Code Trouble
c) Does not cool or temperature cannot be adjusted.
- - -
Description of • Does not cool or temperature cannot be adjusted.
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Does not cool or temperature cannot be adjusted.
Machine
Related
Information
20-678 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]
1) Turn starting switch OFF. 2) Replace relay A15 with normal relay. 3) Turn starting
switch ON. 4) Start air conditioner
Defective compressor Condition is normal. Defective
4 Does condition become normal relay.
Possible clutch relay A15
when relay is interchanged with
Causes and normal relay? Relay is
Standard Condition is abnormal. normal.
Values
1) Turn starting switch OFF. 2) Disconnect connector A05. 3) Connect T-adapter.
4) Turn starting switch ON.
1) Turn starting switch OFF. 2) Disconnect connector ACTH. 3) Turn starting switch
ON. 4) Start air conditioner.
6 Defective thermister Temperature: 25°C 37 - 50kz
Between A03 (Male) (1) and (2)
Temperature: 100°C 3.5 - 4.0kz
1) Turn starting switch OFF. 2) Replace motor with normal motor. 3) Turn starting
switch ON. 4) Start air conditioner
Defective temperature con- Defective
7 Does condition become normal Condition is normal.
trol servo motor motor.
when servo motor is inter-
changed with normal motor? Motor is
Condition is abnormal.
normal.
1) Turn starting switch OFF. 2) Replace compressor with normal compressor. 3) Turn
starting switch ON. 4) Start air conditioner
Defective air
Condition is normal. conditioner
8 Defective air conditioner Does condition become normal compressor.
compressor when air conditioner compres-
sor is replaced with normal Air condi-
compressor? tioner com-
Condition is abnormal.
pressor is
normal.
Turn starting switch OFF. 2) Replace diode D06 with normal diode.
Defective
Condition is normal. diode D06.
9 Defective diode (D06) Replace diode D06 with normal
diode Diode D06 is
Condition is abnormal. normal.
10
Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
control panel
WA320-5H 20-679
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]
Controller
Action Code Failure Code Defective air conditioner
Code Trouble
d) Impossible to switch between recirculated air and fresh air
- - -
Description of • Air conditioner system is defective, so it is impossible to switch between recirculated air and fresh air
Trouble
Machine moni-
tor or control- • No reaction.
ler Reaction
Effect on • Impossible to switch between recirculated air and fresh air
Machine
Related
Information
3 Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
control panel
20-680 WA320-5H
TESTING AND ADJUSTING TROUBLESHOOTING CODE [E-12]
Wiring harness between A03 (Female) (1) and J06 (16), (14) and
A08 (Female) (6) Resistance 1zandbelow
1) Turn starting switch OFF. 2) Disconnect connector ACP1, ACP2, ACM2. 3) Connect
T-adapter.
Resistance between A07
Wiring harness between A07 (Female) (1), C03 (Female) 1Mz and
(Female) (1) and C03 (Female) (1) (1) and chassis ground above
3
Defective air conditioner a Check the control panel, and if any abnormality is found, repair or replace.
control panel
WA320-5H 20-681
white 20-682
TROUBLESHOOTING OF HYDRAULIC,
MECHANICAL SYSTEM
(H MODE)
WA320-5H 20-701
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHART
Step 1. Ask operator questions 2) Find the matching cause in the Causes col-
20-702 WA320-5H
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHART
WA320-5H 20-703
TESTING AND ADJUSTING FAILURE CODE AND CAUSE TABLE
Damper
Motor body
Motor body
High pressure cut-off valve
DA valve
20-704 WA320-5H
Q
Q
Q
Q
Clutch solenoid
Q
Q
Q
Q
Clutch
Q
Q
Transfer
WA320-5H
Q
Q
Q
Q
Q
Q
Q
Work equipment and steering pump
Q
Brake pump
Q
Q
Q
Orbit-roll
Q
Q
Q
Q
Q
Q
Q
Priority valve
Q
Q
Relief valve
TESTING AND ADJUSTING
Steering valve
Q
Safty valve
Q
Q
Q
Q
Steering cylinder
Q
Tire inflation pressure
Q
Accumulator charge valve
Q
Brake valve
Q
Q
Slack adjuster
Q
Q
Brake disc and plate
Axle
Q
Q
Brake piston
Q
Wheel brake linkage
Q
Q
Q
Q
Cut-off relief valve
Q
Q
Q
Q
Unload valve
valve
Cut-off
Q
Q
Q
Q
Check valve
Q
Q
Q
Q
Q
Q
Main relief valve
Q
Q
Q
Q
Lift arm spool
Q
Q
Q
Q
Q
Bucket spool
Q
Q
Q
Q
Suction and safety valve
control valve
Work equipment
Suction valve
Q
Q
Q
Q
Q
Lift arm cylinder
Q
Q
Q
Q
Q
Bucket cylinder
Q
Q
Q
Q
Lift arm PPC valve
Q
Q
Q
Q
Bucket PPC valve
Q
Cushion valve
Troubleshooting No.
H-9
H-8
H-7
H-6
H-5
H-4
H-3
H-2
H-1
H-11
H-26
H-25
H-24
H-23
H-22
H-21
H-20
H-19
H-18
H-17
H-16
H-15
H-14
H-13
H-12
H-10
20-705
TESTING AND ADJUSTING H-1
Transfer
High pressure relief valve
DA valve
forward and reverse solenoid valve
Inching valve
Clutch solenoid
Clutch
Motor body
Motor body
ment, defective seal
Remedy E E E E E E E E E E E E E E E
No. Diagnosis X X X X X X X X X X X X X X X
A
1 Does not travel forward or in reverse Q Q Q Q Q Q Q Q Q Q Q Q Q Q
Q Q Q
Does not travel forward or in reverse, motor makes sound
4
of rotation
20-706 WA320-5H
TESTING AND ADJUSTING H-2
Inching valve
Clutch solenoid
Clutch
Motor body
Motor body
ment, defective seal
Inspection before diagnosis
• Are the oil level in the hydraulic tank and the oil type appro-
priate?
• Is the inching valve linkage adjusting appropriate?
• Is inching valve linkage properly adjusted?
• Is the any external oil leak found around the hydraulic piping,
pump and motor?
Remedy E E E E E E E E E E E E E E E
No. Diagnosis X X X X X X X X X X X X X X X
A
1 Travel speed is slow in both forward and reverse Q Q Q Q Q Q Q Q Q Q Q Q Q
Q
Maximum travel speed in both forward and reverse is
4
approx. 4 km/h
Q
5 Maximum travel speed in both forward and reverse is
approx. 18 km/h
Q Q
Abnormal sound comes from motor in both forward and
6 reverse when travel speed is 10 km/h or more
WA320-5H 20-707
TESTING AND ADJUSTING H
Motor body
Motor body
Transfer
Inching valve linkage
High pressure relief valve
Inching valve
Clutch solenoid
Clutch
Remedy E E E E E E E E E E
No. Diagnosis X X X X X X X X X X
A
1 Rimpull is weak in both forward and reverse Q Q Q Q Q Q Q Q Q
Q Q Q
Rimpull is weak in both forward and reverse, but maximum
4
travel speed is reached the linee.
20-708 WA320-5H
TESTING AND ADJUSTING H-4
Remedy E E E
No. Diagnosis X X X
Q
Machine moves when the direction the lever is at F or R
2
and engine is at Li
WA320-5H 20-709
TESTING AND ADJUSTING H-5
Clutch solenoid
Clutch
Remedy E E E E
No. Diagnosis X X X X
20-710 WA320-5H
TESTING AND ADJUSTING H-6
Obit-roll
Steering Defective hydraulic pump or PTO
Priority valve
Relief valve
Spool
Remedy E E E
No. Diagnosis X X X X X X
Q Q Q Q Q
1 Steering wheel does not turn in both directions (left and
right)
Q
In condition in Item 1, movement of work equipment is
2 abnormal
Q
In condition in Item 1, movement of work equipment is nor-
3
mal
4 Steering wheel turns only in one direction (left or right) Q Q
Q
Emergency steering does not function in both directions
7
(left and right)
a There is a close connection between the steering circuit and work equipment circuit, so if any abnormality is
a If the steering pump is abnormal (broken), check the priority valve at the same time.
felt in the steering, check the operation of the work equipment also.
*1. This warning is given only when the emergency steering is installed.
WA320-5H 20-711
TESTING AND ADJUSTING H-7
Priority valve
Relief valve
Spool
Check for abnormalities
• Measure operating effort of steering wheel and time taken to
turn steering, and check standard judgment value table to
see if there is any abnormality.
Remedy E E E E E E E
No. Diagnosis X X X X X X X
A C C
Q Q Q Q Q
Steering wheel is heavy when turned in both directions (left
1 and right)
Q Q
2 Steering wheel is heavy when turned in one direction (left
and right)
Q Q
Lift arm lifting speed is slow when engine is running at full
4 speed
5 Steering wheel is heavy and there is jerking Q Q
20-712 WA320-5H
TESTING AND ADJUSTING H-8, H-9
H-8
Defect inside steering cylinder (inside surface of cylinder, piston seat, nut, bolt)
Remedy E E E
No. Diagnosis X X X
WA320-5H 20-713
TESTING AND ADJUSTING H-10
H-10 The brake does not work or does not work well
Ask the operator about the following: Cause
Brake linkage
Defective operation of brake piston in axle
Defective brake piston seal in axle
Check abnormality
• Measure the braking force and check referring to the stan-
dard value table if the brake does not work practically.
Remedy E E E E E E E
No. Diagnosis X X X X X X X X X
Q Q Q Q
When the four wheels are jacked up, the axle is placed on a
4 table and the brake is applied at the first forward speed,
only a specific wheel rotates
8 The brake pedal leg-power and stroke are normal, but the Q Q Q Q Q Q Q Q Q
brake does not work well
9 The brake does not work often when the engine is stopped Q Q Q Q Q Q
20-714 WA320-5H
TESTING AND ADJUSTING H-11
Remedy E E E E
No. Diagnosis X X X X
Q Q
When the brake pedal is released, oil is drained from the air
2 bleeder, the circuit oil pressure drops and the brake is
released
Q Q Q
When the four wheels are jacked up, the axle is placed on a
3 table, the engine is stopped, the parking brake is released
and the tires are rotated by hand but a specific tire hardly
rotates
WA320-5H 20-715
TESTING AND ADJUSTING H-12
Remedy C E E E E E E E E E
No. Diagnosis E X X X X X X X X X X X X
1 The bucket cannot operate and the lift arm cannot rise Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q
3 The lift arm can rise without load but cannot rise when
loaded
4 The hydraulic pump causes an abnormal noise Q Q Q Q
Q Q
When the engine is at full throttle, the steering operation is
6 heavy and slow
20-716 WA320-5H
TESTING AND ADJUSTING H-13
H-13 The lift arm moves slowly or the lift arm rising force is
insufficient
Inspection before diagnosis Cause
• Is the stroke of the lift arm control lever appropriate? Tank to Priority Cut-off HST PPC Work equipment
Cylinder
Pump valve valve pump valve valve
Check of Abnormality
• Rising force and speed problem are closely related, and this a b c d e f g h i j k
problem occurs as insufficient rising speed at first. Measure
Remedy C E E E E E E E E
E X
A
No. Diagnosis X X X X X X X X X
Q Q Q Q Q Q Q Q
1 The bucket tilting force and speed are abnormal, and the lift
arm rising speed is slow
Q Q Q
The bucket tilting force and speed are normal, and the lift
2 arm rising speed is slow
Q Q
When the oil temperature rises in No. 1, the lift arm speed
3
becomes very slow
4 The hydraulic pump causes an abnormal noise Q Q
6 The relief oil pressure from the relief valve of the work Q
equipment valves is low
Q
The relief oil pressure from the relief valve of the work
7
equipment valves is too high
WA320-5H 20-717
TESTING AND ADJUSTING H-14
H-14 When rising, the lift arm comes to move slowly at specific
height
Inspection before diagnosis
• 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."
Cause
• Defective seat of suction valve on the lift arm cylinder rod side of work equipment valve
• Oil leak from lift arm cylinder piston seal
Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
Ask the operator about the following:
Does any leaking noise occur inside the lift arm cylinder when hydraulic drift is measured? o The cylinder packing is defective
Diagnosis and Cause
•
after the lift arm cylinder operates to full stroke o The cause is vacuum generated inside the cylinder
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
a Frequent hydraulic drifts o The suction valve on the lift arm cylinder rod side is defective
20-718 WA320-5H
TESTING AND ADJUSTING H-18
Cause
• Improper adhesion of lift arm spool check valve of the work equipment valve
WA320-5H 20-719
TESTING AND ADJUSTING H-19
E E E E E E E
E
Remedy C A
No. Diagnosis X X X X X X X X X X X
1 The lift arm cannot operate and the bucket cannot tilt back Q Q Q Q Q Q Q Q Q Q
2 The bucket can lift the machine but cannot tilt back, or the Q Q Q
lift arm operates but the lift arm cannot tilt back
3 The bucket can tilt back without load but cannot in digging
Q Q Q
or scooping up
4 The hydraulic pump causes an abnormal noise Q Q Q
20-720 WA320-5H
TESTING AND ADJUSTING H-20
Defective operation of safety valve (With suction valve) on bucket cylinder bottom side
Defective unload valve
Check of Abnormality
• Make sure in an actual operation that the tilting-back force is
insufficient.
• Measure the operating speed of the bucket, and make sure
referring to the criterion value table that the speed is abnor-
mal
Remedy C E E E E E E E E
E X
A
No. Diagnosis X X X X X X X X X X
Q Q Q Q Q Q Q Q
The lift arm rising force and speed are abnormal, and the
1 bucket tilting force and speed are abnormal
Q Q Q Q
2 The lift arm rising force and speed are normal, and the
bucket tilting force and speed are abnormal
Q Q Q
The relief oil pressure from the relief valve of the work
6
equipment valves is low
7 The relief oil pressure from the relief valve of the work Q
equipment valves is too high
WA320-5H 20-721
TESTING AND ADJUSTING H-21
Cause
• Expansion of bucket cylinder tube or damage inside
For other abnormal phenomena during bucket operation, see "H-20. The bucket moves slowly or the tilting-back force is insufficient."
Cause
• Defective seat of suction valve on the bucket cylinder rod side of work equipment valve
• Oil leak from bucket cylinder piston seal
Have hydraulic drifts come to occur often suddenly? o Wastes pinched in valve or damage of parts
Ask the operator about the following:
Check of Abnormality
• Refer to the criterion value table and check if the hydraulic drift of the bucket occurs often practically
Cause
• Oil leak in bucket cylinder
• Improper adhesion of safety valve (With suction valve) on the bottom side
• Improper oil tight of bucket spool
20-722 WA320-5H
TESTING AND ADJUSTING H-24
H-24 The bucket wobbles during travel with cargo (The work
equipment valve is set to "HOLD")
Inspection before diagnosis
• Pin of work equipment linkage and "play of bushing" (Is any abnormal noise heard?)
Cause
• Defective seal of bucket cylinder piston
• Defective operation of safety valve (With suction valve) on bucket cylinder rod side. For other abnormal phenomena, refer to diagnoses for
relevant abnormal phenomena.
Cause
• 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
Check of Abnormality Cause
• Refer to the criterion value table and check if the lever oper- PPC
ating efforts are large practically. valve
a
Defective operation of relief valve
E
Remedy C
No. Diagnosis
Q
Becomes heavy in some places during operation regard-
1
less of oil pressure and oil temperature
Q
Becomes heavy overall during operation regardless of oil
2
pressure and oil temperature
WA320-5H 20-723
white 20-724
TROUBLESHOOTING OF ENGINE
(S MODE)
WA320-5H 20-801
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
[Questions]
Sections (A) + (B) in the chart on the right corre-
sponds to the items where answers can be obtained
from the user. The items in B are items that can be
obtained from the user, depending on the user’s
level.
[Check items]
The serviceman carries out simple inspection to nar-
row down the causes. The items under (C) in the
chart on the right correspond to this.
The serviceman narrows down the causes from infor-
mation (A) that he has obtained from the user and
the results of (C) that he has obtained from his own Causes
inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of proba-
bility, starting with the causes that have been marked
as having the highest probability from information
gained from [Questions] and [Check items].
(b) (2) (3)
(a) w
w
Questions
(A) (b)
(c) w
(d) Q
(e) Q
(B)
Check items
(C)
i q
q
shooting
Trouble-
ii
iii q
20-802 WA320-5H
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
n)
jectio
cause, so start troubleshooting for that item to make final confirmation of
the causes.
ive in
*1. For [Confirm recent repair history] in the [Questions] Section, ask
ce ss
the user, and mark the Cause column with # to use as reference
zzle
renc
for locating the cause of the failure. However, do not use this
p ( ex
ent
n no
terfe
when making calculations to narrow down the causes.
r
elem
e
g
jectio
d
er, in
timin
pum
*2. Use the # in the Cause column as reference for [Degree of use
n
, cyli
aner
(Operated for long period)] in the [Questions] section as refer-
ed in
harg
tion
io n
g
ence. As a rule, do not use it when calculating the points for locat-
n rin
ir cle
t
injec
injec
rboc
e iz
ing the causes, but it can be included if necessary to determine
s
pisto
a
ed tu
ctive
ged,
oper
the order for troubleshooting.
ged
Worn
Defe
Clog
Clog
Im p r
Seiz
EEE
*1 Confirm recent repair history
w
*2 Degree of use of machine Operated for long period
WA320-5H 20-803
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
head
ized)
• Excessive injection fuel
tion)
er se
r and
injec
ray
seat
e sp
lung
arge
valve
e
leara (excessiv
fectiv
ce
ck, p
boch
eren
and
le, de
ent
p (ra
n tur
air cle er, interf
valve
nder
e
r
elem
ing
p
uffle
c
pum
pum
n
nozz
e
n tim
e
li
ed m
g, cy
ct of
betw
aner
harg
ction
tion
Impro injection
lve c
jectio
conta
n rin
logg
injec
of air
Q
rboc
je
Legend
a
in
w
per in
c
pisto
per v
: Possible causes (judging from Questions and check items)
ed tu
ctive
ctive
ctive
hed,
t
age
ged
ged
: Most probable causes (judging from Questions and Check items)
Impro
: Possible causes due to length of use (used for a long period)
Worn
Leak
Crus
Defe
Defe
Defe
Clog
Clog
Seiz
: Items to confirm the causes.
EEE E
Confirm recent repair history
w Q Q
Degree of use Operated for long period
w Q Q
Suddenly became black
Color of exhaust gas
w
Gradually became black
Questions
w
Black under light load
w Q Q Q
Engine oil must be added more frequently
Q Q Q Q
Suddenly
Power was lost
Q Q
Gradually
w
Non-specified fuel is being used
w
Noise of interference is heard from around turbocharger
w
Dust indicator lamp is red
Q w Q Q Q Q
Blow-by gas excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after start- w Q
Check items
w
ing engine, temperature of some cylinders is low
w
Match marks on fuel injection pump are out of alignment
w
Seal on injection pump has come off
Q Q w
Clanging sound is heard from around cylinder head
w
Exhaust noise is abnormal
w
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
q
q
When turbocharger is rotated by hand, it is found to be heavy
q q
When air cleaner element is inspected directly, it is found to be clogged
When compression pressure is measured, it is found to be low
q
Speed does not change when operation of certain cylin-
Troubleshooting
ders is stopped
q
When check is made using delivery method, injection tim-
ing is found to be incorrect
Injection pump test shows that injection amount is incorrect q
q
When valve clearance is checked directly, it is found to be
outside standard value
When muffler is removed, exhaust color returns to normal q
q
When control rack is pushed, it is found to be heavy, or
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
20-804 WA320-5H
TESTING AND ADJUSTING METHOD OF USING TROUBLESHOOTING CHARTS
Five causes
Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Causes items in the vertical
column.
Three symptoms
Step 2
Add up the total of Q and w marks where the
horizontal lines for the three symptoms and the
wQw
vertical columns for the causes intersect:
(1) Clogged air cleaner element:
QQ
(2) Air leakage between turbocharger
Q
and head
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner
element]. Follow this column down to the
WA320-5H 20-805
TESTING AND ADJUSTING S-1
eat
Charging rate
lve s
Ambient 100% 90% 80% 75% 70%
filter
temperature
e , va
t
m en
20°C 1.28 1.26 1.24 1.23 1.22
uze
r
a te r
raine
r
linde
f valv
er ele
0°C 1.29 1.27 1.25 1.24 1.23
p ga
ir he
t
g , cy
s
a ct o
-10°C 1.30 1.28 1.26 1.25 1.24
pum
ilter,
ke a
clean
n rin
cont
• The specific gravity should exceed the valve for the charging rate
fuel f
fe e d
l inta
ir
pisto
of 70% in the above table.
a
ctive
trica
ged
ged
ged
• In cold areas the specific gravity must exceed the value for the
Worn
Defe
Clog
Clog
Clog
Elec
charging rate of 75% in the above table.
EEE
Confirm recent repair history
w w Q Q Q
Degree of use of machine Operated for long period
w
Gradually became worse
Ease of starting
w
Starts when warm
Questions
w
Indicator lamp does not light up
w w w
Engine oil must be added more frequently
Q Q
Replacement of filters has not been carried out according to operation Manual
w
Non-specified fuel has being used
Dust indicator lamp is red
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low
Q Q
w
Engine does not pick up smoothly, and combustion is irregular
Blow-by gas is excessive
Check items
Q Q
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
q q
q
When compression pressure is measured, it is found to be low
q
When air cleaner element is inspected directly, it is found to be clogged
q
When fuel filter, strainer are inspected directly, they are found to be clogged
q
When feed pump strainer is inspected directly, it is found to be clogged
Troubleshooting
Replace
Correct
Clean
Clean
Clean
Remedy
20-806 WA320-5H
q
Replace Defe
ctive
q
w w
Replace Defe regu
lator
ctive
a
q
w
w
Replace
E
Defe ltern
ctive a to r
q
w
w
Q
Q
Replace Defe or de
t
WA320-5H
ctive erior
a te d
w
*Adjust Defe injec
t io batte
ctive n no
zzle ry
q
w
w
Q
Q
Replace Defe injec
tion t
ctive
in im ing
q
Q w
Correct Defe jectio
ctive n pu
q
w Q
Q
Clean Clog Leak
a
mp (
r a ck
ged ge, c
w
Replace Defe air b
re a
loggin , plunge
g, air r stu
ctive ther
hole ck)
w
Replace Defe fe e d
p in f
in fue
l pipin
Causes
ctive
boos
ump uel ta
nk g
TESTING AND ADJUSTING
t com
pens
ator
ca n c
el
20-807
S-1
TESTING AND ADJUSTING S-2
witch
• Defective electrical system
ion
nect
• Failure in power train
ircuit
y rela r safety s
ry
batte
l co n
ng c
oid
a
rated
witch
starti
in
otor
solen
y
term
ctive fety relay
ing m
terio
ing s
g of
l cu t
ttery
ar
a tte r
or de
wirin
g ge
start
start
e
a
sa
u
b
b
f
en rin
ctive
ctive
ctive
ctive
ctive
ctive
ctive
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Defe
Brok
E E
Confirm recent repair history
Questions
w Q Q
Degree of use of machine Operated for long period
w
Condition of horn when start- Horn sounds
ing switch is turned ON
w
Horn volume is low
w w
Speed of rotation is low
When starting switch is
w
Makes grating noise
turned to START, pinion
Q Q Q
moves out, but Soon disengages pinion again
Makes rattling noise and does not turn
w Q Q
When starting switch is turned to START, pinion does not move
out
Q w
Check items
w
When starting switch is turned ON, linkage is not actuated
Troubleshooting of defective wiring in starting circuit
q
2) When terminal B and terminal C of starting motor are con-
Troubleshooting
q
3) When terminal B and terminal C of starting safety relay are
connected, engine starts
q
4) When terminal of safety switch and terminal B of starting
motor are connected, engine starts
q
5) There is no 24V between battery relay terminal b and termi-
nal E
q
When ring gear is inspected directly, tooth surface is found to be
chipped
q
Cannot be moved by hand even when linkage of fuel cut solenoid
is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy -
20-808 WA320-5H
TESTING AND ADJUSTING S-2
d)
• Supply of fuel is extremely small
seize
a Standards for use of fuel
• Improper selection of fuel (particularly in winter)
nger
t, key
ank
, plu
shaf
fuel t
strain iston
AMBIENT TEMPERATURE
n fee mp (rack
KIND OF
rive
-4 14 32 50 68°C
le in
iner
FLUID
oid
r
pipin
p
-20 -10 0 10 20°F
e
mp d
er ho
olen
tr
u
leakin tank
s
u
p
fuel
p
n pu
ump
d
cu t s
ASTM D975 No. 2
se d
reath
n
ilter,
in
jectio
g
Diesel fuel
jectio
fuel u
fuel
uel f
fuel
feed
air b
roke
ASTM D975 No. 1
in
t
en, in
n
f
ctive
ctive
oper
fficie
ed b
ged
ged
ged
ged
D e fe
Defe
Br ok
Clog
Clog
Clog
Clog
Im p r
Seiz
I n su
EE E
Confirm recent repair history
Questions
w
There is leakage from fuel piping
w
Mud is stuck to fuel tank cap
w
When starting switch is turned ON, linkage is not actuated
When fuel filter is drained, fuel does not come out
w Q Q Q
When engine is cranked with starting motor,
1) No fuel comes out even when fuel filter air bleed plug is
Check items
loosened
2) No fuel spurts out even when injection pump piping sleeve w w w
nut is loosened
Rust and water are found when fuel tank is drained Q Q Q
Inspect injection pump directly q
q
When control rack is pushed, it is found to be heavy, or does not
return
q
Troubleshooting
q
When feed pump strainer is inspected directly, it is found to be
clogged
When fuel cap is inspected directly, it is found to be clogged q
q
Cannot be moved by hand even when linkage of fuel cut solenoid
is disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
WA320-5H 20-809
TESTING AND ADJUSTING S-2
(3) Exhaust smoke comes out but engine does not start
(Fuel is being injected)
.)
• lack of rotating force due to defective electrical sys-
er etc
tem
)
st u ck
er lev
• Insufficient supply of fuel
k ca p
y
sp r a
, rock
nger
• Insufficient intake of air
stem
l tan
er
ctive
, plu
valve
heat
• Improper selection of fuel and oil
y
el sy
in fue
atter
r
rack
defe
e
tem (
ke air
n
t
leane rainer
m en
li
in fu
ed b
r
mp (
r hole
r
zzle,
e sys
linde
strain
r ele
l inta
iorat
ir
st
n pu
a
n no
n valv
g , cy
a th e
ump
ing,
se d
ctrica
lter,
r
Worn e injectio
Leak e or dete
jectio
e
ed p
clogg
n rin
fuel u
broke
fi
r
air b
air c
le
fuel
e
e
pisto
in
f
ctive
age,
ctive,
oper
ged
ged
ged
ged
ged
ctiv
ctiv
D e fe
D e fe
D e fe
Clog
Clog
Clog
Clog
Clog
Im p r
Defe
EEE E
Confirm recent repair history
w w
Degree of use of machine Operated for long period
Suddenly failed to start
When engine is cranked, abnormal noise is heard from around w
w
cylinder head
Questions
Q Q
Engine oil must be added more frequently
Non-specified fuel is being used
Replacement of filters has not been carried out according to Oper- w w w
w w
ation Manual
w
Rust and water are found when fuel tank is drained
w
Dust indicator lamp is red
w
Indicator lamp does not light up
Q
Starting motor cranks engine slowly
Q
Mud is stuck to fuel tank cap
When fuel lever is placed at FULL position, it does not contact stopper
w
When engine is cranked with starting motor,
Check items
1) Little fuel comes out even when fuel filter air bleed plug is
loosened
2) No fuel comes out even when fuel filter air bleed plug is w w Q
w
loosened
There is leakage from fuel piping
When exhaust manifold is touched immediately after starting w
w
engine, temperature of some cylinders is low
When fuel filter is drained, no fuel comes out
Remove head cover and check directly q
When control rack is pushed, it is found to be heavy, or does not q
q
return
When compression pressure is measured, it is found to be low
When fuel filter, strainer are inspected directly, they are found to q q
Troubleshooting
be clogged
When feed pump strainer is inspected directly, it is found to be q
q
clogged
q
When air cleaner element is inspected directly, it is found to be clogged
q
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or operation q
q
is too heavy
q
Speed does not change when operation of certain cylinders is stopped
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Correct
Correct
Clean
Clean
Clean
Clean
Clean
Remedy
20-810 WA320-5H
TESTING AND ADJUSTING S-3
ca p
eat
pray
• Improper fuel used
lve s
l pipin uel tank
tive s
d va
efec
er
a ce
nger
e an
n
ent
leakin er hole in
r
g
li
aine
zle, d
p plu
r
reath nce
elem
f valv
train
d
p str
ed tu ring, cylin
a
ed in ction noz
pum
g fue
clear
er, s
aner
a ct o
pum
rg
o ch a
ction
t
air cle
il
cont
f
feed
air b
fuel
inje
n
b
je
pisto
r
ctive
oper
ged,
ged
ged
ged
ged
ged
Worn
Defe
Clog
Clog
Clog
Clog
Clog
Clog
Im p r
Seiz
Seiz
EEE E E
Confirm recent repair history
Degree of use of machine Operated for long period
Replacement of filters has not been carried out according to Oper- w w w
Questions
ation Manual
w w w w
w
Non-specified fuel is being used
Q w Q Q
Engine oil must be added more frequently
w w
Engine pick-up suddenly became poor
w
Rust and water are found when oil is drained
w
Dust indicator lamp is red
Q w
Noise of interference is heard from around turbocharger
w w w Q
Blue under light load
Color of exhaust gas
w
Black
w
Clanging sound is heard from around cylinder head
Check items
w
Mud is stuck to fuel tank cap
There is leakage from fuel piping
w w Q
High idling speed under no load is normal, but speed suddenly
drops when load is applied
There is hunting from engine (rotation is irregular) Q w Q Q
w Q
When exhaust manifold is touched immediately after starting
engine, temperature of some cylinders is low
Blow-by gas excessive w
When air cleaner element is inspected directly, it is found to be q
clogged
When fuel filter, strainer are inspected directly, they are found to q
be clogged
When feed pump strainer is inspected directly, it is found to be q
Troubleshooting
clogged
Speed does not change when operation of certain cylinders is q
q
stopped
q q
When control rack is pushed, it is found to be heavy, or does not return
q
When compression pressure is measured, it is found to be low
When turbocharger is rotated by hand, it is found to be heavy
When valve clearance is checked directly, it is found to be outside q
q
standard value
q
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump is operated, operation is too light or too heavy
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Clean
Clean
Clean
Clean
Remedy
WA320-5H 20-811
TESTING AND ADJUSTING S-4
tc.)
• Insufficient supply of fuel
ver, e
t u ck)
a If there is overheating and the engine stops,
• Overheating
ker le
ger s
od
carry out troubleshooting for overheating.
k
e, roc
el tan
plun
ting r
ring
ke y
t
a If the engine stops because of a failure in the
• Failure in power train
men
l pipin ton
(valv
rack,
t bea
in fu
nnec
pis
haft,
quip
ainer
g
stem
iner
leakin d pump
mp (
hole
power train, carry out troubleshooting for the
shaf
n , co
train
s
e
e
p str
a
y
tank
p driv
chassis.
n pu
r
r
rank
r train
t
g fue
ther
ia
pisto
gear
s
valve
fe e
auxil
pum
filter,
el in
Failu e injectio
a
c
pum
powe
eized
eized
ized
eized
amic
r
um p
eed
air b
fu
fu e l
e l
t
e
n dyn
f
en fu
en, s
en, s
en, s
en, s
re in
en p
ged,
fficie
ged
ged
ged
ctiv
Broke
Defe
Brok
Brok
Brok
Brok
Brok
Brok
Clog
Clog
Clog
Clog
Insu
EE
Confirm recent repair history
Degree of use of machine Operated for long period
Abnormal noise was heard and w w w w w w Q Q w
w Q Q
engine stopped suddenly
Condition when engine
Questions
w Q Q
Engine overheated and stopped
stopped
w Q Q Q
Engine stopped slowly
There was hunting and engine stopped
w w
Replacement of filters has not been carried out according to Oper-
ation Manual
Q Q Q Q
w
Non-specified fuel is being used
w
Fuel level lamp lights up
Q Q w
Fuel tank is found to be empty
w
When feed pump is operated, operation is too light or too heavy
w
Mud is stuck to fuel tank cap
Check items
w w
Engine rotates, but stops when power train is operated
w
Does not turn at all
w w
When it is attempted to turn Turns in opposite direction
by hand using barring tool
w
Moves amount of backlash
w w
Shaft does not turn
w w Q Q
Rust and water are found when tank is drained
Troubleshooting of chassis
q q
q
Remove oil pan and inspect directly
q
Remove head cover and inspect directly
q
When gear train is inspected, it does not turn
Troubleshooting
q
When feed pump strainer is inspected directly, it is found to be
clogged
Inspect feed pump directly q
q
When control rack is pushed, it is found to be heavy, or does not
return
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Clean
Clean
Clean
Remedy -
Add
20-812 WA320-5H
TESTING AND ADJUSTING S-5
um p
ozzle
• Defective governor mechanism
eed p nd feed p
and n
• Defective electric governor mechanism
ump
a
ank
l tank
k
connected, carry out troubleshooting for the
fuel t
c
r
erno
rol ra
rnor
n fue
chassis.
een f
le in
strain r
v
adjus n of gove
e
low
cont
o
twee
er
strain
t of g
betw
er ho
o
k
n of
uit be
ficien eed is to
n
tm e n
l in ta
ump
ircuit
reath
ilter,
Defe e operatio
io
c
a t
ir
ed p
ir in c
c
t fu e
oper
fuel f
air b
sp
in
e
ir
idling
ged a
f
g ed a
ctive
ctive
ged
ged
ged
ctiv
Insuf
D e fe
Defe
Clog
Clog
Clog
Clog
Clog
Low
EE
Confirm recent repair history
w w w Q
Degree of use of machine Operated for long period
Q w Q Q Q Q
Occurs at a certain speed range
Condition of hunting
Occurs on slopes w
w w
Replacement of filters has not been carried out according to Oper-
ation Manual
w
Q Q
Fuel tank is found to be empty
w w
Rust and water are found when tank is drained
Leakage from fuel piping
w
When feed pump is operated,
Check items
w
1) No response, light, return is quick
w w
2) No response, light, return is normal
w w
Engine speed sometimes rises too far
w w
Engine is sometimes difficult to stop
Seal on injection pump has come off
When governor level is moved it is found to be stiff q q
When injection pump is tested, governor is found to be improperly q
adjusted
Troubleshooting
q q
return
When fuel tank cap is inspected directly, it is found to be clogged
When feed pump strainer is inspected directly, it is found to be q
clogged
When fuel filter, strainer are inspected directly, they are found to q
be clogged
Correct
Correct
Adjust
Adjust
Adjust
Adjust
Clean
Clean
Clean
Remedy
Add
WA320-5H 20-813
TESTING AND ADJUSTING S-6
ent
justm
tive a eat
y
• Improper fuel used
ragm
plung tive spra
es
(if non-specified fuel is used, output drops)
ank
d
iaph
d valv
e
t
a If there is overheating and lack of output, carry
• Lack of output due to overtaking
g, cy terferenc
e l
efec
tor d
m
in fu
er
hrag
t
er
ing
m en
jectio nozzle, d
e n sa
er
strain
le
r
out troubleshooting for overheating.
a n ce
linde
ip
f valv
strain
diap
o
er, in
er ele
p
h
ump
om p
l
th e r
e
clear
ump
linka
fu
a ct o
gate
harg
filter,
p
lean
o st c
n
brea
io
n
ed p
n rin
valve
west
lever
t
cont
rboc
injec
air c
fuel
o
ir
le
b
e
pisto
a
f
ed tu
ctive
ctive
ctive
ed in
oper
ged,
fuel
ged
ged
ged
ged
ged
Worn
D e fe
D e fe
D e fe
Bent
Clog
Clog
Clog
Clog
Clog
Clog
Im p r
Seiz
Seiz
E EEE E
Confirm recent repair history
w w w
Degree of use of machine Operated for long period
Q Q Q Q Q Q
Suddenly
Questions
w
Gradually
Engine oil must be added more frequently
Replacement of filters has not been carried out according to Oper- w w w
w w w w
ation Manual
w
Non-specified fuel is being used
w w
Dust indicator lamp is red
w
Black
Color of exhaust gas
w
Black under light load
w Q
Noise of interference is heard from around turbocharger
w Q Q Q
Blow-by gas excessive
Check items
Q Q Q Q
engine, temperature of some cylinders is low
w
There is hunting from engines (rotation is irregular)
Q w
Clanging sound is heard from around cylinder head
w
High idling speed of engine is low
Leakage from fuel piping
When air cleaner element is inspected directly, it is found to be q
q
clogged
q q
When turbocharger is rotated by hand, it is found to be heavy
When compression pressure is measured, it is found to be low
When fuel filter, strainer are inspected directly, they are found to q
be clogged
q
Troubleshooting
q
standard value
q
When level is placed at FULL position, it does not contact stopper
q
When feed pump is operated, operation is too light or too heavy
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy
20-814 WA320-5H
TESTING AND ADJUSTING S-7
head
)
eized
n)
• Excessive injection of fuel
jectio
r and
, plun at
y
ger s
sp r a
se
ive in
arge
valve
ctive
e
s
renc
b o ch
( e xce
(rack
defe
and
ent
terfe
n tur
valve
der
n ce
r
zzle,
elem
iming
um p
um p
uffle
er, in
twee
leara
li
n no
ion p
tion p
ed m
g , cy
ct o f
aner
tion t
harg
e
lve c
b
jectio
conta
t
clogg
n rin
ir cle
injec
injec
of air
injec
rboc
v a
pisto
in
a
ed tu
ctive
ctive
ctive
hed,
oper
oper
age
ged
ged
Worn
Leak
D e fe
D e fe
Defe
Crus
Clog
Clog
Impr
Impr
Seiz
EEE E
Confirm recent repair history
w Q Q
Degree of use of machine Operated for long period
w Q Q
Suddenly became black
Color of exhaust gas
w
Gradually became black
Questions
w
Black under light load
w Q Q Q
Engine oil must be added more frequently
Q Q Q Q
Suddenly
Power was lost
Q Q
Gradually
w
Non-specified fuel is being used
w
Noise of interference is heard from around turbocharger
w
Dust indicator lamp is red
Q w Q Q Q Q
Blow-by gas excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after starting w Q
Check items
w
engine, temperature of some cylinders is low
w
Timing lock on fuel injection pump does not match
w
Seal on injection pump has come off
Q Q w
Clanging sound is heard from around cylinder head
w
Exhaust noise is abnormal
w
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy q
When air cleaner element is inspected directly, it is found to be q
q q
clogged
When compression pressure is measured, it is found to be low
q
Troubleshooting
q
found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly, it is found to be outside q
q
standard value
When muffler is removed, exhaust color returns to normal
When control rack is pushed, it is found to be heavy, or does not q
return
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Adjust
Adjust
Adjust
Clean
Remedy
WA320-5H 20-815
TESTING AND ADJUSTING S-8
rger
• Abnormal combustion of oil
o ch a
)
gine
• External leakage of oil
Turb
ss en
l
d
n se a
• Wear of lubrication system
r hea
ce
h o se
st e m
surfa
r
er le
coole
r o ke
linde
y
ther
r (lin
se a l
s
e), b
g
r oil
il coo pan or cy
a ke
lu
a
linde
d
end
ain p
e
seal,
o
ing
, guid
m int
or br
e
te r
il pip
e
w er
g , cy
oil dr
in
oil fil
rear
ring
in fro
( st e m
ther
Worn al at turb
r
oil
at blo
le
om o
n rin
iston
rom
from
m
brea
ke n
d
o
valve
e
pisto
se a l
su ck
f
f
, bro
en p
en o
age
age
age
age
ged
se
Worn
Worn
Worn
Worn
Leak
Leak
Leak
Leak
Br ok
Br ok
D u st
Clog
E EE E
Confirm recent repair history
w Q
Degree of use of machine Operated for long period
w Q
Oil consumption suddenly increased
Q w Q
Engine oil must be added more frequently
Questions
w w
Engine oil becomes contaminated quickly
w w Q Q
Exhaust smoke is blue under light load
w
Excessive
Amount of blow-by gas
w w w w
None
w
Area around engine is dirty with oil
w Q
There is oil in engine cooling water
When exhaust pipe is removed, inside is found to be dirty with oil
w
Check items
w
rises
Clamps for intake system are loose
When compression pressure is measured, it is found to be low q q
When breather element is inspected, it is found to be clogged with q
q q q q
dirty oil
Troubleshooting
q
There is external leakage of oil from engine
q q
Pressure-tightness test of oil cooler shows there is leakage
q
Excessive play of turbocharger shaft
q
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be dirty with q
oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
20-816 WA320-5H
TESTING AND ADJUSTING S-9
en d
• Improper oil used
rbine
• Operation under excessive load
tu b e
se
e r tu
drain
r
er ho
r line
harg
e a th
linde
er oil
e
rboc
lack
id
e gu
r
er, b
g, cy
harg
e is b
at tu
turbo r
le
, valv
er
il coo
eath
c
n rin
se a l
mok
oil filt
valve
r
pisto
b
ust s
ctive
ged
ged
ged
ged
Worn
Worn
E xh a
Defe
Clog
Clog
Clog
Clog
E E E
Confirm recent repair history
w
Degree of use of machine Operated for long period
Questions
Q
Engine oil must be added more frequently
w
Non-specified fuel is being used
w
Black under light load
Color of exhaust gas
w Q Q Q
Black
w
Carry out troubleshooting for "Exhaust smoke is black".
Excessive
Check items
Q w Q
None
w
When oil filter is inspected, metal particles are found
w
When exhaust pipe is removed, inside is found to be dirty with oil
Engine oil temperature rises quickly
q
found to be clogged with dirty oil
q
When oil filter is inspected directly, it is found to be clogged
q
When oil cooler is inspected directly, it is found to be clogged
q
Turbocharger oil drain tube is clogged
Excessive play of turbocharger shaft
When safety valve is directly inspected, spring is found to be
catching or broken
Replace
Replace
Replace
Replace
Clean
Clean
Clean
Remedy -
WA320-5H 20-817
TESTING AND ADJUSTING S-10
n)
• Excessive injection of fuel
jectio
kage
n)
al ins ead cove el filter
pisto
ive in
rol lin
mp (
u
ing, f
r
ce ss
co n t
nger
d pu
el pip
y
g
spra
p (ex
p plu
timin
fu e l
e fe e
m fu
eh
nt of
lder
pum
m
n
id
u
jectio
insid
tion p
e fro
le ho
stme
tion
fuel in
a ka g
l
oil se
e
n o zz
injec
injec
adju
of fu
le
ctive
ctive
ctive
ctive
ctive
ctive
age
rnal
Leak
Defe
Defe
Defe
Defe
Defe
Defe
Exte
EE E
Confirm recent repair history
Degree of use of machine Operated for long period
More than for other machines of w Q
Questions
Q Q
Condition of fuel same model
consumption
Q Q
Gradually increased
w Q Q Q
Suddenly increased
Q
Black
Exhaust smoke color
w
White
w
Seal on injection pump has come off
There is irregular combustion
w Q
Check items
w
engine, temperature of some cylinders is low
w
Match mark on injection pump is misaligned
Q w w
There is external leakage of fuel from engine
Q w
Engine oil level rises and smells of diesel fuel
Engine low idling and high idling speeds are high
Injection pump measurement shows that injection amount is q
excessive
Speed does not change when operation of certain cylinders is q
stopped
Troubleshooting
q
found to be incorrect
q
Remove head cover and inspect directly
Remove feed cover and inspect directly
When engine speed is measured, low and high idling speeds are q
found to be high
Replace
Replace
Correct
Correct
Correct
Adjust
Adjust
Adjust
Remedy
20-818 WA320-5H
TESTING AND ADJUSTING S-11
oil co gasket
ck
-ring
r blo
ler
ad
o
d, he
re, O
linde
ng
y pitti
r hea
in cy
ler co
train
se d b
linde
r a cks
il coo
ower
y
s ca u
nal c
en o
en p
en c
Brok
Brok
Brok
Hole
Inter
E E
Confirm recent repair history
Questions
Q Q Q
Degree of use of machine Operated for long period
Q Q
Suddenly increased
Oil level
Q Q
Gradually increased
w Q Q
Hard water is being used as cooling water
Engine oil level has risen, oil is cloudy white
w
Check items
Remedy
WA320-5H 20-819
TESTING AND ADJUSTING S-12
sens ing
Type of oil ambient temperature
ip
n
pan
oil pa
or
ulic p
g
-30 -20 -10 0 10 20 30 40°C
razin
e oil
nsor
e
r valv
ydra
side
SAE30CD
ipe b
sure
strain rnal
en su ipe insid
e
an
f valv
vel s
ed h
er in
mp
Defe e regulato
jou
tion p
er
il
il
oil pu
l in o
r u sh
oil le
Engine oil
relie
oil filt
ing,
oil p
in
SAE10W-30CD
c
bear
r , fu e
c
of oil
ctive
ctive
ctive
ing,
ged
ged
ged
ctiv
ctiv
SAE15W-40CD
Worn
Wate
Leak
L a ck
Defe
Defe
Defe
Brok
Clog
Clog
Clog
EE E
Confirm recent repair history
Degree of use of machine Operated for long period
w
Questions
Q Q
ation Manual
w Q
Non-specified fuel is being used
w Q
Caution lamp lights up
w w w w Q Q Q
Lights up at low idling
w
Condition when oil pressure Lights up at low, high idling
lamp lights up
w w Q Q
Lights up on slopes
w
Sometimes lights up
Check items
w w
There is crushing, leakage from hydraulic piping (external)
w
Oil level sensor lamp lights up
w
When oil level in oil pan is inspected, it is found to be low
w Q
Metal particles are found when oil is drained
w
Metal particles are stuck to oil filter element
Oil is cloudy white or smells of diesel oil
q q
q q q
When oil filter is inspected, it is found to be clogged
Carry out troubleshooting for
q
Troubleshooting
q
guide is broken
When oil level sensor is replaced, oil level sensor lamp goes out
When oil pressure is measured, it is found to be within standard q
valve
Replace
Replace
Replace
Correct
Correct
Adjust
Adjust
Clean
Clean
Clean
Clean
Remedy -
Add
20-820 WA320-5H
TESTING AND ADJUSTING S-13
r
• Water in oil (milky white)
co ve
• Fuel in oil (diluted, and smells of diesel fuel)
al
head
nt se
• Entry of oil from other component
p
et
pum
ipme
ide in g inside
ce
g a sk
surfa
e
sleev
le ho O-ring
ction
y equ
lock
head
pipin
se a l
je
der b
lder
xiliar
ore,
, dam er head,
g
rear
st a t
from
n
y pitti
p au
cylin
ler c
m
fu e l
n o zz
pum
il coo
de b
r
ylind
side
h e
f
t
o
s ma
ctive
ctive
ctive
ks in
en o
en c
age
ctiv
Worn
Leak
Defe
Defe
Defe
Crac
Brok
Brok
Hole
E EE E
Confirm recent repair history
Questions
w Q Q Q Q
Degree of use of machine Operated for long period
w w w
There is oil in radiator cooling water
w Q Q
Fuel must be added more frequently
w
Exhaust smoke is white
When engine is first started, drops of water come from muffler
Leave radiator cap open. When engine is run at idling, an abnor- w Q
Check items
w
damper chamber
w w w
Oil level goes down in hydraulic tank
w
Engine oil smells of diesel fuel
Water temperature is low
q
q
Pressure-tightness test of oil cooler shows there is leakage
q
Pressure-tightness test of cylinder head shows there is leakage
q
When compression pressure is measured, it is found to be low
Troubleshooting
q
damaged
q
Remove head cover and inspect directly
q
Remove injection pump and inspect directly
q q
Defective contact with thermostat seal valve
Remove oil pan and check directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
WA320-5H 20-821
TESTING AND ADJUSTING S-14
e
ratur
a Carry out troubleshooting for chassis.
n)
• Rise in oil temperature in power train
uge
t ope
t
aske
m pe
il coo pulley
e ga
r fins
s no
ad g
oil te
ratur
n fa n
ler
(doe
diato
d, he
valve
erter
e
e
ing
, wor
r
emp
o st a t
e
r
ed ra
r hea
o
crush p
conv
t
sure
y pitt
a
en o
to r c
pum
ling w
Lack e water t
ping
therm
e
pres
brok
radia
de b
rque
ylind
ater
p
o
li
o f co
s
s ma
ctive
ctive
in to
en w
ged,
ged,
en c
ged
ctiv
belt
D e fe
D e fe
D e fe
Br ok
Br ok
Clog
Clog
Clog
Hole
Rise
F an
EE EE
Confirm recent repair history
w Q Q
Degree of use of machine Operated for long period
w w Q Q
Suddenly overheated
Questions
Condition of overheating
w Q
Always tends to overheat
w
Rise quickly
Water temperature gauge
w
Does not go down from red range
w
Radiator water level sensor lights up
w
Fan belt whines under sudden load
w
Cloudy white oil is floating on cooling water
w
Cooling water flows out from overflow hose
Q w
Excessive air bubbles inside radiator, water spurts back
w
Engine oil level has risen, oil is cloudy white
Check items
w w
There is play when fan pulley is rotated
w
Radiator shroud, inside of underguard are clogged with dirt or mud
w
When light bulb is held behind radiator, no light passes through
w
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Power train oil temperature enters red range faster than engine w
water temperature
excessive
Temperature difference between top and bottom radiator tanks is q
q
slight
Troubleshooting
q
When water filler port is inspected, core is found to be clogged
q
When function test is carried out on thermostat, it does not open
q
When water temperature is measured, it is found to be normal
When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set pressure q
q
is found to be low
q
When compression pressure is measured, it is found to be low
Remove oil pan and inspect directly
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy -
Add
20-822 WA320-5H
TESTING AND ADJUSTING S-15
.)
head
ine)
ition)
er, etc
General causes why abnormal noise is made
s eng
)
eized
f pos
tion)
nder
• Abnormality due to defective parts
er lev
er les
d cyli
• Abnormal combustion
injec
out o
ger s
m (va rance
, rock
er (lin
• Air sucked in from intake system
er an
sive
, plun
oard
e
a
e
renc
e n ce
e cle
lv
ylind
ozzle
fan b p (exces
harg
ing b
(rack
terfe
h
erfer
f valv
ing, c
c
cklas
n
in
ump
r, int
g
io
ton r
um
ent o
in
lt
a
c t
b
h
valve
d inje
tion p
p
uffler
s
arge
of pis
train
d bu
tion
tw
justm
air be
amic
boch
seize
injec
injec
fa n ,
gear
seize
wear
a d
n dyn
f
r
rmed
ct ins
age o
ed tu
ctive
ctive
ctive
ssive
oper
ged,
ing,
Broke
Defe
Defe
Defo
Defe
Defe
Miss
Clog
Impr
Leak
Exce
Seiz
E
Confirm recent repair history
Q Q
Degree of use of machine Operated for long period
Questions
Q Q Q
Gradually occurred
Condition of abnormal noise
Q Q
Suddenly occurred
w
Non-specified fuel is being used
w
Engine oil must be added more frequently
w Q Q
Black under light load
Color of exhaust gas
w w
Black
w
Metal particles found in oil filter
w
Blow-by gas excessive
w
Noise of interference is heard from around turbocharger
Check items
w
engine, temperature of some cylinders is low
Q Q Q Q Q Q
Seal on injection pump has come off
w w
Abnormal noise is loud when accelerating engine
Clanging sound is heard from around cylinder head
Leakage of air between turbocharger and cylinder head, loose w
w
clamp
Vibrating noise is heard from around muffler
q
q
When compression pressure is measured, it is found to be low
q q
When turbocharger is rotated by hand, it is found to be heavy
Remove gear cover and inspect directly
Speed does not change when operation of certain cylinders is q
Troubleshooting
stopped
When control rack is pushed, it is found to be heavy, or does not q
q
return
q
Injection pump test shows that injection amount is incorrect
Fan is deformed, belt is loose
When valve clearance is checked, it is found to be outside q
q
standard value
q
Remove cylinder head cover and inspect directly
When muffler is removed, abnormal noise disappears
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Remedy
WA320-5H 20-823
TESTING AND ADJUSTING S-16
ck)
)
noise is made".
ction
tc. stu
General causes why vibration is excessive
ion
l inje
ver, e
ligne
cu sh
• Defective parts (abnormal wear, breakage)
r)
e fue
ker le
mpe
misa
• Improper combustion
ke n
aring
e, roc
essiv
a
, bro
• Abnormal combustion
aft (d
a in
(valv
in be
(exc
t
bolts
sh
ngine utput sh
e r
ackla
w
m
, ma
ump
syste
o
nting
d p
ain b
g rod
tion p
o
n
alve
ing
m ou
a
side
mic v
r
b u sh
ectin
injec
r
art in
gine
e a
dyna
e
conn
g
ca m
ctive
er of
e en
en p
oper
ctive
Worn
Worn
Loos
Cent
Defe
Brok
Impr
Defe
EEE
Confirm recent repair history
Q Q
Degree of use of machine Operated for long period
Questions
Q Q Q
Suddenly increased
Condition of vibration
Q Q
Gradually increased
w w
Non-specified fuel is being used
w w
Metal particles are found in oil filter
Q Q
Metal particles are found when oil is drained
Q Q
Oil pressure is low at low idling
Check items
Q Q Q Q
Vibration occurs at mid-range speed
w Q
Vibration follows engine speed
w
Exhaust smoke is black
Seal on injection pump has come off
q
q
Remove oil pan and inspect directly
q
Remove side cover and inspect directly
Troubleshooting
q
Inspect directly for loose engine mounting bolts, broken cushion
Inspect inside of output shaft (damper) directly
When face runout and radial runout are inspected, they are found q
q
to be incorrect
q
Remove front cover and inspect directly
q
Remove head cover and inspect directly
Injection pump test shows that injection amount is incorrect
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Adjust
Remedy
20-824 WA320-5H
30 DISASSEMBLY AND ASSEMBLY
WA320-5H 30-1.
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
a:
N: Tools with new part numbers, newly
developed for this model. This mark gives guidance or precau-
R: Tools with upgraded part numbers, tions when doing the procedure.
2:
remodeled from already available tools This mark stands for a specific coating
for other models. agent to be used.
Blanks: Tools already available for other models,
3:
used without any modification. This mark indicates the specified
3) Circle mark (Q) in sketch column: torque.
5:
A circle mark means that a sketch of the spe-
This mark indicates an amount of oil or
cial tool is presented in the section of
water to be added.
a:
This mark gives guidance or precau-
tions when doing the procedure.
This mark shows that there are instruc-
[*1] :
tions or precautions for installing parts.
6:
This mark shows oil or water to be
drained.
30-2 WA320-5H
DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL
a:
available, can be substituted with com-
mercially available tools. This mark gives guidance or precau-
2) Distinction of new and existing special tools tions when doing the procedure.
2:
N: Tools with new part numbers, newly This mark stands for a specific coating
developed for this model. agent to be used.
R: Tools with upgraded part numbers,
3:
remodeled from already available tools This mark indicates the specified
for other models. torque.
Blanks: Tools already available for other models,
5:
used without any modification. This mark indicates an amount of oil or
water to be added.
3) Circle mark (Q) in sketch column:
A circle mark means that a sketch of the spe-
cial tool is presented in the section of Sketches of special tools
a:
This mark gives guidance or precau-
tions when doing the procedure.
6:
This mark shows oil or water to be
drained.
WA320-5H 30-3d
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN
CARRYING OUT OPERATION
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precau-
tions given below when carrying out the operation.]
1. Precautions when carrying out removal work
• If the coolant contains antifreeze dispose of it correctly.
• After disconnecting hoses or tubes, cover them or fit blind 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 discon-
necting 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 of 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 enter-
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
number Plug (nut end) Nut (elbow end)
02 07376-70210 02789-00210
03 07376-70315 02789-00315
04 07376-70422 02789-00422
05 07376-70522 02789-00522
06 07376-70628 02789-00628
3) If the part is not under hydraulic pressure, the following corks can be used.
30-4 WA320-5H
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
a When using the machine for the first time after repair or long storage, follow the same procedure.
3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
WA320-5H 30-5d
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
a New/remodel:
Extremely useful if available, can be substituted with commercially available part.
N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available
for other models.
a Tools marked Q in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL
Blank: Tools already available for other models, used without any modification.
TOOLS).
New/remodel
Necessity
Symbol
Sketch
Q’ty
Component Part No. Part Name Nature of work, remarks
1 795-799-1131 Gear t 1
Fuel injection pump Removal, installation of fuel injection
t
assembly pump
2 795-799-1390 Remover 1
q
A
Nozzle holder assembly 3 795-799-1171 Puller 1 Removal of nozzle holder assembly
1 790-201-2840 Spacer t 1
t Q
Press fitting of output shaft bearing
2 793T-417-1110 Push tool 1 N
• 790-101-5311 • Plate 1
3
• 790-101-5221 • Grip 1
• 01010-51225 • Bolt 1
6 799-401-3200 Adapter q 1
7 02789-00315 Cap q 1
Removal, installation of parking
q
brake cylinder rod pin
8 799-101-5160 Nipple 1
9 790-190-1500 Pump q 1
01010-80860 Bolt t 6
t Q
2 Axle shaft oil seal support
793T-422-1420 Seal support 2 N
Axle housing assembly H
01010-80860 Bolt t 6
t Q
Adjustment of axle shaft bearing
4 793T-422-1430 Holder 1 N
shim
30-6 WA320-5H
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
New/remodel
Necessity
Symbol
Sketch
Q’ty
Component Part No. Part Name Nature of work, remarks
t
Removal, installation of pinion shaft
6 797-101-1211 Wrench 1
nut
t
No-load operating torque of anti-slip
7 793-615-1100 Wrench 1
differential
t Q
Press fitting of pinion shaft bearing
9 797T-423-1320 Push tool 1
t Q
Differential assembly H Press fitting of pinion shaft cage oil
10 797T-423-1130 Push tool 1
seal
t
790-102-2303
2 or Wrench assembly Removal, installation of cylinder
1
790-102-3802 (for steering) head
t
Press fitting of cylinder head bush-
790-201-1702 Push tool kit 1 ing
790-101-5021 • Grip 1
01010-50816 • Bolt 1
4
790-201-1821 • Push tool (boom) 1
Hydraulic cylinder
U
assembly 790-201-1831 • Push tool (bucket) 1
• Push tool
790-201-1741 1
(steering)
790-101-5021 • Grip 1
01010-50816 • Bolt 1
5 790-201-1630 • Plate (boom) 1
• Push tool
790-201-1550 1
(steering)
WA320-5H 30-7d
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
New/remodel
Necessity
Symbol
Sketch
Q’ty
Component Part No. Part Name Nature of work, remarks
q
Ring
796-720-1680 (boom and bucket) 1
q
Ring
07281-01589 (boom and bucket) 1
7
t
Wrench assembly
790-102-4300 (for boom and 1
8 bucket)
790-102-4310 Pin t 2
t
Collection and supply of air condi-
799-703-1200 Service tool kit 2
tioner refrigerant
t
Vacuum pump
799-703-1100 1
(100 V)
t
1 Vacuum pump
799-703-1110 1
(220 V)
t
Vacuum pump
799-703-1120 (240 V) 1
t
Installation of operator's X
cab glass
799-703-1400 Gas leak tester 1
t
Adjustment of clearance of window
2-1 793-498-1120 Clear plate 2
glass
30-8 WA320-5H
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOLS
D2 Push tool
9JF00891
D4 Push tool
9JF00892
WA320-5H 30-9d
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOLS
H1-1 Push tool aWhen using this tool, connect H1-2 to it.
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these skeches.
9JF00902
H1-2 Push tool aWhen using this tool, connect H1-1 to it.
9JF01421
30-10 WA320-5H
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOLS
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these skeches.
H2 Seal support
9JF01422
H2 Seal support
9JF01423
WA320-5H 30-11d
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOLS
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these skeches.
H3 Push tool
9JF00899
H4 Holder
9JF01424
30-12 WA320-5H
DISASSEMBLY AND ASSEMBLY SKETCH OF SPECIAL TOOLS
Note: Komatsu cannot accept any responsibility for special tools manufactured according to these skeches.
H9 Push tool
DXW06324
CWH10643
WA320-5H 30-13d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
REMOVAL, INSTALLATION OF
FUEL INJECTION PUMP
ASSEMBLY
SPECIAL TOOLS
AJS00169
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part Name
1 795-799-1131 Gear t 1
t
A
2 795-799-1390 Remover 1
k
Lower the work equipment to the ground
and stop the engine.
k
Disconnect the cable from the negative (-)
terminal of the battery.
AJF00957
30-14 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
11. Remove lubrication tubes (17) and (18). 15. Remove fuel injection pump nut (22) and washer
AJF00958
AJF00961
AJS00171
AJF00962
ING, Testing and adjusting fuel injection tim- 17. Remove fuel injection pump bracket (24).
ing.
AJF00963
AJF00960
WA320-5H 30-15d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
9JF01042
AJS00172
30-16 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
[*3]
3
AJF00963
Engine stop solenoid terminal:
0.98 - 1.27 Nm {0.1 - 0.13 kgm}
3
5. Install washer (23) and tighten fuel injection
Engine stop solenoid bracket mounting
into the case. a Adjust the engine stop solenoid. For details, see
k
TESTING AND ADJUSTING, Adjusting engine
Tighten the nut to the following stop solenoid.
torque temporarily so that it will
[*5]
3
not damage the timing pin.
3
Fuel tube joint bolt (on fuel filter side):
Temporary tightening torque of
19.6 - 29.4 Nm {2.0 - 3.0 kgm}
fuel injection pump nut:
12.5 ± 2.5 Nm {1.27 ± 0.25 kgm}
• Bleeding air
Bleed air from the fuel system.
9JF01043
WA320-5H 30-17d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF NOZZLE HOLDER ASSEMBLY
REMOVAL, INSTALLATION OF
4. Remove spill tube (2). [*2]
NOZZLE HOLDER ASSEMBLY
SPECIAL TOOLS
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part Name
AJS00174
A 3 795-799-1171 Puller t 1
REMOVAL
k
Lower the work equipment to the ground
and stop the engine. 5. Loosen and remove nozzle holder assembly (3).
1. Open the engine right and left side covers. enter the mounting part of the nozzle holder
assembly
2. Remove air cleaner (10).
AJS00175
AJS00173
AJF00965 9JF01048
30-18 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF NOZZLE HOLDER ASSEMBLY
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
[*2]
[*3]
3 Nozzle holder:
60 Nm ± 9 Nm {6.1 ± 0.9 kgm}
• Bleeding air
Bleed air from the fuel system.
WA320-5H 30-19d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY
REMOVAL, INSTALLATION OF
CYLINDER HEAD ASSEMBLY
SPECIAL TOOLS
New/Remodel
AJS00150
Necessity
Sketch
Q'ty
Symbol Part No. Part Name
3 795-799-1171 Puller t 1
t
A
4 790-331-1110 Wrench 1
REMOVAL 4. Remove cotter pin (10) and nut (11), and then
remove engine stop solenoid rod (12) from the
k
fuel injection pump.
Stop the vehicle on a level place and set the
safety bar to the frame.
k
Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k
Disconnect the cable from the negative (-) AJF00957
terminal of the battery.
6 Coolant: 17 l
5. Disconnect the following engine stop solenoid
30-20 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY
7. Remove engine stop solenoid bracket (43). [*4] 12. Remove hose (19) on the upper side of the after-
cooler. [*7]
AJS00151
AJS00141
9. Remove the mounting bolts of heater relay (16). 14. Remove the muffler according to the following
procedure.
1) Remove 4 mounting bolts (21).
2) Remove 4 mounting bolts (22).
3) Remove drain tube mounting bolt (29) and
drain tube (24).
AJS00152
AJS00154
AJS00153
WA320-5H 30-21d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY
15. Lift off muffler and bracket assembly (23). 1) Lift off turbocharger and exhaust manifold
4
assembly (32).
4
Muffler and bracket assembly: 35 kg
Turbocharger and exhaust mani-
fold assembly: 40 kg
AJS00155
AJS00158
AJS00159
AJS00156
AJS00157
AJS00160
30-22 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY
22. Remove alternator bracket (40) and thermostat 28. Disconnect 6 fuel injection tubes (33). [*14]
and housing assembly (41) together. [*12]
AJS00163
AJS00161
AJS00164
AJS00162
AJS00165
WA320-5H 30-23d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY
AJS00166
9JF01044
9JF01048
9JF01045
9JF01046
30-24 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY
• Carry out installation in the reverse order to times according to the following procedure.
3
removal.
[*1] Exhaust manifold mounting bolt:
3
1st time: Tighten the bolts to 24 ± 4 Nm
Ground terminal: {2.45 ± 0.41 kg} in the order
59 - 74 Nm {6 - 7.5 kgm} of 1 - 12.
2nd time: Tighten the bolts to 43 ± 6 Nm
[*3]
[*5]
3
Gasket sealant (ThreeBond 1208E or
Air hose clamp: equivalent)
3
9.8 ± 0.5 Nm {1.0 ± 0.05 kgm}
Radiator hose clamp:
[*7] 8.8 ± 0.5 Nm {90 ± 5 kgcm}
3
10.5 + 0.5 Nm {107 ± 5 kgcm}
Mounting torque of alternator terminal
[*8] E11: 5.9 - 9.80 Nm {0.6 - 1.0 kgm}
3
tube (25): 35 ± 5 Nm {3.57 ± 0.51 kgm}
Mounting bolt of turbocharger lubrication Thermostat housing mounting bolt:
tube (26): 24 ± 4 Nm {2.45 ± 0.41 kgm} 24 ± 4 Nm {2.45 ± 0.41 kgm}
[*13]
WA320-5H 30-25d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY
5
side): 24 ± 4 Nm {2.45 ± 0.41 kgm} Threads and seat of mounting bolt:
Fuel injection tube nut (on nozzle holder Engine oil
3
side): 30 ± 5 Nm {3.06 ± 0.51 kgm}
Cylinder head bolt:
[*15] 1st time: Tighten the bolts to 90 ± 5
3
Nm {9.18 ± 0.51 kgm} in
Spill tube: 9 Nm {0.9 kgm} the order of 1 - 26.
2nd time: Tighten the bolts to 120 ±
[*16] 5 Nm {12.24 ± 0.51 kgm}
3
in the order of 3, 6, 11, 14,
Nozzle holder:
19, and 22.
60 ± 9 Nm {6.12 ± 0.92 kgm}
3rd time:
[*17] • When using tool A4:
3
Using angle tightening
Cylinder head cover mounting bolt: wrench A4, tighten the bolts
24 ± 4 Nm {2.45 ± 0.41 kgm} by 90° ± 5° in the order of 1 -
26 (Angle tightening).
of the block.
2. Sling cylinder head assembly (58) and set it to
the cylinder block.
9JF01046 9JF01050
30-26 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CYLINDER HEAD ASSEMBLY
CLP01522
5. Install rocker arm assembly (56) and tighten the • Bleeding air
Bleed air from the fuel system.
a Check that the ball of the adjustment screw
mounting bolts with the fingers.
9JF01049
WA320-5H 30-27d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF ENGINE ASSEMBLY
REMOVAL, INSTALLATION OF
6) Disconnect wiring connector B05 (4) and
ENGINE ASSEMBLY clamp (102) from the front side of the engine
hood.
REMOVAL
k
Stop the vehicle on a level place and set the
safety bar to the frame.
k
Lower the work equipment to the ground,
stop the engine, apply the parking brake, AJS00004
and put chocks under the tires.
k
Disconnect the cable from the negative (–)
terminal of the battery.
6 Coolant: 17 l
7) Disconnect wiring connectors B06 (5), B07
(6), and B08 (7) from the front side@of the
engine hood.
2. Remove the engine hood assembly according to
the following procedure. 8) Disconnect 2 windshield washer hoses (8).
1) Remove right and left fenders (1).
2) Remove right and left brackets (100).
3) Remove right and left inspection covers
(101).
AJS00005
AJS00002
AJS00006
AJS00003
30-28 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF ENGINE ASSEMBLY
10) Remove 2 condenser mounting bolts (9) 14) Remove fuel tank air bleeding hose (13)
AJS00010
AJS00007
AJS00008
9JF01052
AJS00009
WA320-5H 30-29d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF ENGINE ASSEMBLY
ropes, etc.
3) Remove right and left stays (110) and (111). AJS00013
4) Remove bulkhead (34).
30-30 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF ENGINE ASSEMBLY
AJS00015 11. Disconnect heater hose clamp (47) and air con-
ditioner hose clamp (48).
AJS00019
AJS00017
WA320-5H 30-31d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF ENGINE ASSEMBLY
16. Disconnect 3 fan motor hose clamps (50) from 19. Remove all damper cover mounting bolts (54).
a You may remove 1 more fan motor hose a Do not disconnect the engine from the HST
the engine block. [*10]
clamp from the HST pump. pump unit by removing HST pump mounting
bolts (55).
If the engine assembly is disconnected from
AJS00020
AJS00023
AJS00021
9JF01053
18. Place pipe [1] across the frame, and then secure
HST pump assembly (53) and pipe [1] with lever
block [2].
AJS00022
30-32 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF ENGINE ASSEMBLY
3
fan motor hose (120) along the outside of engine
mount (121), and then lift up engine assembly Precleaner mounting bolt:
(57) carefully. 8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*2]
3
a Take care not to damage the radiator, after-
connected. Mounting torque of alternator terminal
E11: 5.9 - 9.80 Nm {0.6 - 1.0 kgm}
cooler, and hydraulic oil cooler.
4
[*6]
3
Engine assembly: 650 kg
Starting motor + terminal:
17.7 - 24.5 Nm {1.8 - 2.5 kgm}
[*7]
3
AJS00024
Radiator hose clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
[*8]
WA320-5H 30-33d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF ENGINE ASSEMBLY
[*11]
AJF01019
AJF01035
30-34 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL, INSTALLATION OF
6. Remove 2 radiator assembly upper mounting
RADIATOR ASSEMBLY bolts (5).
REMOVAL
k
Stop the vehicle on a level place and set the
safety bar to the frame.
k
Lower the work equipment to the ground,
AJS00041
stop the engine, apply the parking brake,
and put chocks under the tires.
6 Coolant: 17 l
2. Remove air aftercooler. For details, see 7. Raise radiator assembly (6) and pull it out to the
AJS00042
AJS00039
INSTALLATION
5. Disconnect radiator outlet hose (4). [*2]
• Carry out installation in the reverse order to
removal.
[*1] [*2]
3
AJS00040
Radiator hose clamp:
8.8 ± 0.5 Nm {90 ± 5 kgcm}
WA320-5H 30-35d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF AIR AFTERCOOLER
REMOVAL, INSTALLATION OF
3. Remove bulkhead (34) between the cooler and
AIR AFTERCOOLER engine according to the following procedure.
k
ropes, etc.
Stop the vehicle on a level place and set the 2) Remove right and left stays (31) and (32).
safety bar to the frame.
3) Remove bulkhead (34).
k
Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
AJS00029
AJS00027
4. Remove 2 upper and lower mounting bolts (40)
of the left side of the oil cooler.
5. Disconnect upper air hose (5). [*1]
AJS00030
AJS00028
30-36 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF AIR AFTERCOOLER
[*1]
AJS00032
AJS00033
WA320-5H 30-37d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY
REMOVAL, INSTALLATION OF
HYDRAULIC OIL COOLER
ASSEMBLY
REMOVAL
k
AJS00035
Stop the vehicle on a level place and set the
safety bar to the frame.
k
Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k
Slowly loosen the oil filler cap of the hydrau- 5. Remove 2 oil cooler upper mounting bolts (7)
lic tank to release the residual pressure in
a Move plate (36) and remove the left lower
and 2 lower mounting bolts (8).
the hydraulic tank.
bolts.
1. Perform Removal, installation of air aftercooler,
Steps 1 - 5 (on the 1st page), to remove the parts
to the upper air hose.
2. Remove bracket (35).
3. Disconnect oil cooler upper hose (5) and lower
hose (6). (At this time, the plate between the
AJS00036
a Since oil will leak, prepare an oil receiver and
flange and oil cooler comes off, too.)
AJS00034
AJS00037
30-38 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY
INSTALLATION
a Take care not to damage the core.
6. Raise oil cooler (9) and pull it out to the left.
[*1]
WA320-5H 30-39d
REMOVAL, INSTALLATION OF COOLING FAN AND FAN MOTOR
DISASSEMBLY AND ASSEMBLY ASSEMBLY
REMOVAL, INSTALLATION OF
3. Disconnect IN-port hose (4), OUT-port hose (5),
COOLING FAN AND FAN
a Since oil will leak, prepare an oil receiver and
and Dr-port hose (6).
MOTOR ASSEMBLY
an oil stop plug.
REMOVAL
k
Stop the vehicle on a level place and set the
safety bar to the frame.
k
Lower the work equipment to the ground,
stop the engine, apply the parking brake, AJF01203
and put chocks under the tires.
k
Slowly loosen the oil filler cap of the hydrau-
lic tank to release the residual pressure in
the hydraulic tank.
1. Open grille (1) and remove cover (2). 4. Remove 1 fan mounting bolt (7) and cooling fan
(8). [*1]
AJS00027
AJF00950
AJF00951
AJF01202
30-40 WA320-5H
REMOVAL, INSTALLATION OF COOLING FAN AND FAN MOTOR
DISASSEMBLY AND ASSEMBLY ASSEMBLY
[*1]
3 Mounting bolt:
27 - 34 Nm {2.8 - 3.5 kgm}
AJF01204
WA320-5H 30-41..d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF FUEL TANK ASSEMBLY
REMOVAL, INSTALLATION OF
6. Disconnect spill hose (9), fuel supply hose (10),
FUEL TANK ASSEMBLY and fuel return hose (11) from the top of fuel tank
k
takes in the mounting position when install-
k
tank.
Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k
Disconnect the cable from the negative (–)
terminal of the battery.
AJF01271
1. Drain the fuel.
AJS00027
AJF01270
AJF01205
30-42 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF FUEL TANK ASSEMBLY
8. Open the engine left side cover and disconnect 11. Lower transmission jack [1] and sling fuel tank
wiring connector R21 (6) from the top of fuel tank (13). Pull out transmission jack [1] and remove
AJF01206
AJF01272
AJF01207 INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
12. [*2]
When installing, pass fuel tank air bleeding hose
(4) from underside before clearance is elimi-
nated.
• Refilling with fuel (Fuel tank)
AJF01208 Add fuel through the fuel filler.
WA320-5H 30-43d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF TRANSFER
REMOVAL, INSTALLATION OF
4. Disconnect accumulator charge valve drain hose
TRANSFER (3).
REMOVAL
k
Stop the vehicle on a level place and set the
safety bar to the frame.
k
Lower the work equipment to the ground,
AJF01362
stop the engine, apply the parking brake,
and put chocks under the tires.
k
Press the brake pedal at least 100 times to
release the residual pressure in the brake
accumulator circuit.
k
Disconnect the cable from the negative (–)
terminal of the battery.
5. Disconnect PA-port hose (4) and PB-port hose
(5) from the brake valve.
6. Disconnect clutch valve P-port hose (6).
1. Remove the operator's cab assembly. For
7. Disconnect transfer cooler hose (7).
details, see Removal, installation of operator's
cab.
2. Remove the HSS pump and 4-gear pump
assembly. For details, see Removal, installation
of HSS pump and 4-gear pump assembly.
3. Disconnect motor 1 drain hose (1) and motor 2
drain hose (2).
AJF01363
9JF01412
8. Disconnect clamps (8), (9), and (10).
AJF01364
30-44 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF TRANSFER
AJF01365
AJF01368
INSTALLATION
AJF01366
• Carry out installation in the reverse order to
removal.
[*1] [*2]
11. Sling the transfer assembly temporarily and a When installing the drive shaft, check that the
remove 2 transfer cushions (13) on right and left key way of the spider cap is fitted in the key way
sides, and then remove the 2 transfer mounting of the mating yoke, and then tighten the mount-
a After removing the right cushion, remove a When installing the rear drive shaft, check that
bolts on right and left sides. [*3] ing bolts.
accumulator and bracket assembly (14). the lateral runout of the rear axle and transfer
from each other is less than 3 mm. If the runout
is 3 mm or larger, shift the transfer cushion and
transfer mount to reduce the runout.
[*3]
WA320-5H 30-45d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
DISASSEMBLY, ASSEMBLY
3) Disconnect wiring connectors T10 (3) and
OF TRANSFER ASSEMBLY T07 (4).
SPECIAL TOOLS
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part Name
AJF01210
1 790-201-2840 Spacer t 1
• 790-101-5311 • Plate 1
3
• 790-101-5221 • Grip 1
• 01010-51225 • Bolt 1
t Q
4) Disconnect clutch port hose (5).
793T-417-1120 Push tool 1 N
t
D 5) Remove the 6 mounting bolts and bracket
4 790-101-5221 Grip 1 assembly (6).
01010-81225 Bolt t 1
6 799-401-3200 Adapter q 1
7 02789-00315 Cap q 1
8 799-101-5160 Nipple q 1
DISASSEMBLY
1. Drain the transfer oil.
AJF01212
AJF01209
30-46 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
AJF01213
AJF00413
9JF00928
AJF00414
WA320-5H 30-47d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
AJF00415
AJF01216
8. Belleville springs
1) Turn over the case and remove cage (18)
AJF01217
AJF01215
AJF01218
30-48 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
AJF01219 AJF01222
shims.
AJF01220
AJF01223
11. Coupling
1) Remove the mounting bolts and holder (26).
2) Remove coupling (27). 3) Remove dust seal (30) and oil seal (31) from
cage (32).
4) Remove outer race (33).
AJF01221
AJF01224
WA320-5H 30-49d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
13. Spacer 15. Removal of HST motor 1 shaft and ring gear
1) Remove spacer (34). 1) Remove HST motor 1 shaft and ring gear
assembly (36).
AJF01225
AJF01227
AJF01226
2) Remove snap ring (39).
AJF01229
30-50 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
3) Supporting ring gear (40) and using push 18. Disassembly of output shaft and gear assembly
tool [8] and a press, push out HSS motor 1 1) Using push tool [9], remove rear bearing
shaft (41). (50).
2) Remove gear (51) and spacer (52).
AJF01230
AJF01233
AJF01234
AJF01231
AJF01235
AJF01232
WA320-5H 30-51d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
20. Disassembly of carrier assembly 22. Removal of HST motor 2 gear and bearing
assembly
a Keep the ball carefully.
1) Remove shaft (56) ball (57) from carrier (58).
1) Remove HST motor 2 gear and bearing
2) Remove 2 thrust washers (59), planetary assembly (67).
gear (60), and bearing (61) (at 3 places).
AJF01239
AJF01236
AJF01237
AJF01240
AJF01238
30-52 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
24. Removal of HST motor 1 gear and outer races 25. Disassembly of HST motor 1 gear and outer
* Do not remove HST motor 1 gear shaft (70). (If it races
is removed forcibly and reused, it can cause a 1) Using puller [17], remove 2 outer races (73)
trouble.) from HST motor 1 gear (72), and then
1) Using puller [14], remove bearing (71) and remove spacer (74).
HST motor 1 gear and outer races (72). 2) Remove seal ring (75).
9JF01333 9JF01335
9JF01336
9JF01334
9JF01337
WA320-5H 30-53d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
AJF01241
1. Rear case
1) Press fit outer race (80) of the output shaft to
rear case (79).
AJF01243
30-54 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
3. Installation of HST motor 2 gear and bearing 5. Bearing and HST motor 1 gear
assembly 1) Using push tool [22] and the press, press fit
1) Install HST motor 2 gear and bearing assem- bearing (78).
bly (67).
9JF01340
AJF01239
9JF01341
WA320-5H 30-55d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
2
places).
Seal ring and O-ring: 2) Install pinion shaft (56) to carrier (58), match-
Grease (G2-LI) ing their ball holes to each other, and then
install ball (57).
AJF01238
AJF01236
2
(h) on shaft (70)].
2
Mounting bolt: Adhesive (LT-2)
3
Mounting bolt: Adhesive (LT-2)
3
Mounting bolt:
Mounting bolt: 137 - 196 Nm {14 - 20 kgm}
88.2 - 107.8 Nm {9 - 11 kgm}
AJF01246
AJF01245
30-56 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
9. Assembly of HST motor 1 shaft and ring gear 4) Using push tool [25] and the press, press fit
assembly bearing (42).
1) Install bearing (45) to ring gear (40), and
then install snap ring (44).
AJF01250
AJF01247
AJF01251
AJF01248
bearing (flanged).
AJF01252
AJF01249
WA320-5H 30-57d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
10. Installation of HST motor 1 shaft and ring gear 4) Using tool D2 and the press, press fit rear
AJF01253
AJF01256
3 Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
AJF01254
AJF01257
2) Rotate the shaft and set spacer (52).
3) Install output gear (51).
AJF01255
30-58 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
9JF00819
AJF01258
3 Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
AJF01260
AJF01259
2 Gasket sealant:
ThreeBond 1207B or equiva-
lent
WA320-5H 30-59d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
AJF01219
AJF01225
2
15. Clutch discs, plates, and springs
O-ring: Grease (G2-LI)
1) Install end plate (25).
AJF01220 AJF01266
2) Install 7 discs (22), 7 wave springs (24), and 2) Install the O-ring and piston (20).
AJF00420 AJF01267
30-60 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
AJF01268
18. Cage
gradually.
• Installed load of belleville springs
(7-piece set): 21.500 N {2,190 kg}
3 Mounting bolt:
245 - 308 Nm {25 - 31.5 kgm}
AJF01215
WA320-5H 30-61d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
2
ing, check that the dispersion of clear-
Lips and clearances of oil seal ances at 3 places (j) is 0.15 mm or less.
and dust seal: Silicone grease If the dispersion is large, the bearing is
(ThreeBond 1855 or equivalent) not installed normally or there is another
cause. In this case, eliminate the cause
and reduce the dispersion to 0.15 mm or
less.
AJF01224
AJF01262
9JF01342
9JF00844
3 Mounting bolt:
4.80 ± 0.98 Nm {0.5 ± 0.1 kgm}
30-62 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
2
ance (k) + 0.15 mm to 0.20 mm
5) Insert selected shim (29) between cage Spline of coupling: Lubricant
assembly (28) and the front case. containing molybdenum
6) Tighten the cage mounting bolts. disulfide (LM-G)
3 Mounting bolt:
245 - 308.7 Nm {25 - 31.5 kgm}
AJF01263
AJF01221
2
4.9 - 6.7 Nm {0.5 - 0.7 kgm}
Spline of output shaft: Lubricant
containing molybdenum
disulfide (LM-G)
AJF01264
AJF00415
WA320-5H 30-63d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
AJF01269
AJF00413
3
ance between the parking brake housing
and transfer case is eliminated, tighten Mounting bolt:
3 Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
AJF00497
30-64 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF TRANSFER ASSEMBLY
AJF01213
AJF01211
2
(4).
Spline of HST motor 2: Lubricant
containing molybdenum disul-
fide (LM-G)
3 Mounting bolt:
245 - 309 Nm {25.0 - 31.5 kgm}
AJF01210
a Do not apply LM-G to the spline of HST
2) Sling and install HST motor 1 (7).
motor 1.
3 Mounting bolt:
245 - 309 Nm {25.0 - 31.5 kgm}
AJF01212
AJF01209
WA320-5H 30-65d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY
REMOVAL, INSTALLATION OF
4. Disconnect the upper hose (4) and lower hose
PARKING BRAKE ASSEMBLY (5) of transfer oil cooler (1).
REMOVAL
k
Stop the vehicle on a level place and set the
safety bar to the frame.
k
Lower the work equipment to the ground,
AJS00045
stop the engine, apply the parking brake,
and put chocks under the tires.
k
Keep in mind that "the parking brake is
removed" = you cannot apply the parking
brake.
AJS00044
5. Remove 3 mounting bolts (6) of transfer oil
cooler (1).
30-66 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF PARKING BRAKE ASSEMBLY
[*1]
WA320-5H 30-67d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY
DISASSEMBLY, ASSEMBLY
2. Plates, discs, and springs
OF PARKING BRAKE 1) Remove 2 clamping bolts (3) and 2 spacers
ASSEMBLY
a Since the spring tension is applied,
(4).
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part Name
1
AJF00509
• 790-101-5301 • Plate
3
• 790-101-5221 • Grip 1
D • 01010-51225 • Bolt 1
4 790-101-5221 Grip t 1
01010-81225 Bolt t 1
AJF00510
AJF00507
3. Cam plate
1) Remove cam plate (8).
AJF00511
AJF00508
30-68 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY
4. Ball 6. Pin
1) Remove 6 balls (9). 1) Remove pin (12).
7. Dust seal and oil seal
1) Remove dust seal (13) and oil seal (14).
AJF00512
AJF00517
5. Lever
1) Remove the mounting bolt and lever (10).
8. Oil seal and bearings
1) Remove oil seal (15).
2) Remove 2 bearings (16) from parking brake
case (17).
AJF00513
AJF00522
AJF00514
WA320-5H 30-69d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY
ASSEMBLY
a Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with transfer
AJF00522
AJF00523
2
4. Lever
Lips and clearances of oil seal
and dust seal: Silicone grease 1) Install levers (11) and (10).
(ThreeBond 1855 or equivalent) (Perform the work with the gasket removed.)
AJF00524
9JF00851
30-70 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY
3 Mounting bolt:
27 - 34 Nm {2.8 - 3.5 kgm}
AJF00511
on the housing.
5. Balls
and plates.
(Perform the work with the gasket removed.)
6. Cam plate
WA320-5H 30-71d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF PARKING BRAKE ASSEMBLY
2) Using push tool [1], press plate (5) lightly 2) Install the O-ring and cover (1).
2
with a press and install 2 spacers (4) and 2
O-ring: Grease (G2-LI)
a Take care not to press plate (5) too
clamping bolts (3).
3 Mounting bolt:
a Press plate (5) until it is flush with the
much and not to damage it.
98 - 122.5 Nm {10 - 12.5 kgm}
normally.
3 Clamping bolt:
19.6 - 27.4 Nm {2.0 - 2.8 kgm} AJF00507
AJF00916
8. Strainer
1) Install strainer (2).
AJF00508
30-72 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF FRONT AXLE ASSEMBLY
k
Stop the vehicle on a level place and set the
safety bar to the frame. AJS00061
k
Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k
Release the remaining pressure in the
brake accumulator circuit. For details, see
TESTING AND ADJUSTING, Releasing
remaining pressure in hydraulic circuit. 4. Disconnect wiring connector F14 (3) and clamp
(10).
AJS00062
AJS00059
larly. AJS00064
4 Front wheel (1 side): 340 kg
AJS00060
WA320-5H 30-73d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF FRONT AXLE ASSEMBLY
3
bolts on both sides and front axle assembly (6).
[*3] Front axle 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.
AJS00065
30-74 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF REAR AXLE ASSEMBLY
REMOVAL, INSTALLATION OF
REAR AXLE ASSEMBLY
REMOVAL
k
Stop the vehicle on a level place and set the AJS00051
safety bar to the frame.
k
Lower the work equipment to the ground
and stop the engine.
k
Release the remaining pressure in the
brake accumulator circuit. For details, see
TESTING AND ADJUSTING, Bleeding air
from brake accumulator circuit. 5. Disconnect brake hose (2) from the frame.
6. Disconnect 2 grease tubes (3).
7. Disconnect grease tube (10).
1. Raise the chassis with the work equipment (See 8. Remove 3 grease fittings (11). (If they are not
Removal, installation of front axle assembly, 1.) removed, the axle assembly will collide with them
and set blocks [1] under the rear frame in front of when the axle assembly is pulled out backward
the rear wheel. in step 12.)
2. Lower the work equipment to the ground horizon-
tally and raise the rear part of the chassis, and
then support the counterweight on blocks [1]
and jack [2].
3. Set blocks [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. AJS00053
AJS00050
AJS00052
larly.
WA320-5H 30-75d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF REAR AXLE ASSEMBLY
AJS00054
AJS00057
AJS00055
AJS00058
AJS00056
30-76 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF REAR AXLE ASSEMBLY
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
• Bleeding air
Bleed air from the brake system. For details, see
TESTING AND ADJUSTING, Bleeding air from
brake system.
WA320-5H 30-77d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY
DISASSEMBLY, ASSEMBLY
2) Sling rear support (30) temporarily and
OF AXLE HOUSING remove cover (31).
ASSEMBLY
SPECIAL TOOLS
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part Name AJS00082
t Q
1
793T-422-1440 Push tool 1 N
01010-80860 Bolt t 1
t Q
2
H 793T-422-1420 Seal support 1 N 3) Remove thrust plate (32) and rear support
t
01010-80860 Bolt 1
(30).
t Q
4) Remove brake tube and hose assembly (33).
793T-659-1110 Push tool 1
t
3
790-201-2750 Spacer 1
4 793T-422-1430 Holder t 1 N Q
DISASSEMBLY
a The following photos and illustrations show the
AJS00084
rear axle housing as an example.
1. Draining oil
6
27 l
Axle (Each of front and rear axles):
will not lean when the housing assembly assemblies, make match marks on the
on one side is removed. housings and differential case so that
the housing assemblies will not be mis-
taken.
AJS00083
AJS00098
30-78 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY
2) Set axle housing assembly (1) with the brake 3) Remove end plate (38).
side up. 4) Remove sun gear shaft (39).
AJS00099 AJS00087
AJS00089
AJS00085
AJS00090
AJS00086
WA320-5H 30-79d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY
9JF00881
6. Axle shaft
1) Sling axle housing assembly (5) about 20
mm.
will be removed.
AJS00093
30-80 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY
9JF00883
AJS00095
9JF00882
2) Using push tool [7], push out shaft (16) with
a press.
AJF00633
WA320-5H 30-81d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY
3) Pull roll pin (15) out of removed shaft (16). 2) Remove bushing (52) from rear axle support
(30) and remove packing (53) from the
retainer.
AJF00634
AJS00110
AJS00097
AJS00109
30-82 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY
ASSEMBLY
a Adjust tool H2 so that its top will lightly
3) Install tool H2 under oil seal (8).
1. Axle housing and axle shaft touch oil seal (8) and the clearance will
1) Press fit bearing outer races (12) and (13) to be even.
axle housing (11).
9JF00885
9JF00882
9JF00884
WA320-5H 30-83d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY
2
hole of the axle shaft and mounting bolt.
Fitting part of oil seal and bearing: 2) Turning axle housing (11), tighten holder
Axle oil mounting bolt (2).
a After installing the housing, leave tool H2 3 Mounting bolt:
installed until stop 4). 490 - 607.6 Nm {50 - 62 kgm}
2
measure the starting effort at hole (d) of axle
Outside of bearing: Axle oil housing (11).
• Starting effort
9JF01492
9JF00886
30-84 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY
9JF01493
4. Planetary carrier
AJS00097
WA320-5H 30-85d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY
AJS00103
AJS00101
5. Ring gear
1) Install ring gear (9) to axle housing (11) and
ring gear.
AJS00104
AJS00102
30-86 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY
3 Mounting bolt:
490 - 608 Nm {50 - 62 kgm}
AJS00089
2) Sling and install planetary carrier assembly
(3).
k
When installing the planetary carrier,
take care not to catch your fingers in
the gear.
AJS00105
WA320-5H 30-87d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY
5) Rotate axle housing (11) 10 or more turns to 3) Install 2 discs (36), 2 wave springs (37), and
fit it. Then, using push-pull gauge [10], mea- 2 plates (35) in order from the bottom,
marked with A.
• Starting effort each other and set them in the range
7. Brake
1) Install end plate (38).
2) Install sun gear shaft (39).
AJS00108
AJS00087
9JF01495
30-88 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY
2
axle housing and differential housing and
apply gasket sealant all over them. Inside of packing: Grease (G2-LI)
2
(Apply thinly)
Mating faces of housings: Gasket
sealant (LOCTITE 515 or equiv-
alent)
3 Mounting bolt:
490 - 608 Nm {50 - 62 kgm}
3 Mounting bolt:
245 - 309 Nm {25.0 - 31.5 kgm}
WA320-5H 30-89d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF AXLE HOUSING ASSEMBLY
AJS00084
3 Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
AJS00082
3 Drain plug:
127.4 - 176.4 Nm {13 - 18 kgm}
30-90 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
DISASSEMBLY, ASSEMBLY
2. Removal of long cage assembly (For only front
OF DIFFERENTIAL differential)
ASSEMBLY 1) Set the axle assembly on block [1] and jack
[30].
New/Remodel
when it needs to be removed.
Necessity
Sketch
3) Remove long cage assembly (24).
Q'ty
Symbol Part No. Part Name
6 797-101-1211 Wrench t 1
7 793-615-1100 Wrench t 1
11 793-520-2202 Installer q 3
14 799-401-3100 Adapter t 1
t
3. Disassembly of long cage assembly (For only
16 799-101-5160 Nipple 1 front differential)
1. Draining oil
2) Using push tool [3], push shaft (26) with a
WA320-5H 30-91d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
3) Remove snap ring (28) and ring (29), and 6) Using forcing screw [2], guide bolt [4],
9JF00857
AJS00123
6. Differential assembly
1) Place and stabilize differential assembly on
AJS00114
AJS00113
30-92 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
7) Using forcing screws [2], remove top cover 8. Disassembly of front cage assembly (For front
(21). differential)
1) Remove nut (31) and holder (33).
AJS00115
9JF00858
AJS00122
AJS00117
AJS00126
AJS00116
WA320-5H 30-93d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
4) Remove bearing (37), outer races (38) and 2) Remove the mounting bolts and both bearing
(39) from cage (40). carriers (44), using guide bolt [4] and forcing
shims.
9JF00860
AJS00119
AJF00545
AJS00120
AJF01187
AJS00118
30-94 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
11. Removal of differential carrier assembly 12. Disassembly of standard differential carrier
AJS00127
9JF01496
AJS00121
AJS00128
WA320-5H 30-95d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
3) Place the case assembly upside down and 6) Remove 4 spherical washers (54) and 4 pin-
AJF00553
AJS00129
AJS00132
AJS00130
AJS00133
AJS00131
30-96 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
9) Using a puller, remove outer race (61) from 2) Remove 20 mounting bolts (46) and bevel
AJS00128
AJS00134
AJS00136
WA320-5H 30-97d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
5) Remove 2 plates (67) and 2 discs (68). 8) Remove pinion gear assembly (71).
AJS00137 AJS00140
AJF00566
AJS00138
AJF01293
AJS00139
30-98 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
AJS00142 AJS00147
12) Remove 2 plates (76) and 2 discs (77). 14) Using push tool [11], remove outer race (79)
from inside of case (64). Similarly, using
push tool [11], remove the outer race from
inside of cover (63).
AJS00143
AJS00145
AJS00144
AJS00146
WA320-5H 30-99d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
2
damage. Coat their sliding surfaces with axle oil
(AX080, see Operation Manual, Komatsu genu- Before installing the discs and
ine parts list) before installing. plates, soak them in axle oil
(AX080, see Operation Manual,
Komatsu genuine parts list).
1. Assembly of anti-slip differential assembly
(Optional)
1) Install outer race (79) to case (64).
2) Similarly, install outer race (79) to cover (63).
AJS00149
AJS00146
AJS00142
AJS00148
AJF01293
30-100 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
7) Install 4 pinion gears (72) to spider shaft 10) Install pressure ring (69).
(73).
AJS00138
AJF00566
AJS00140
AJS00137
9) Install side gear (70).
AJS00139
WA320-5H 30-101d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
12) Selection of thickness of plate 14) Adjust the clearance of the side gear in the
i) Using depth gauge [12], measure dis- axial direction.
tance (d) between the end of case (64) i) Measure clearance (e) between the side
a Replace the plates on both sides so a There are washers 2.0 mm and 2.1
mm. new one.
AJF01186
AJF01184
13) Fit washer (66) to cover (63), and then install 9JF01497
AJF01185
30-102 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
15) Install cover (63). 17) Measure the no-load operation torque.
2
i) Install sun gear shafts (14) to both sides
Mounting bolt: of anti-slip differential assembly (83).
98 - 123 Nm {10 -12.5 kgm}
ii) Fix the sun gear shaft on one side and
install tool H7 to the sun gear shaft on
the other side.
iii) Install torque wrench [13] to tool H7 and
freely.
AJS00135 • No-load operation torque:
Max. 10 Nm {Max. 1.0 kgm}
• If the no-load operation torque
exceeds the standard value, disas-
semble the anti-slip differential again
and perform 11) SELECTION OF
THICKNESS OF PLATE and 15)
ADJUSTMENT OF SIDE GEAR IN
AXIAL DIRECTION.
16) Turn over the assembly and install bevel
3
9JF01498
Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
AJS00127
WA320-5H 30-103d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
2. Assembly of standard differential carrier assem- 5) Install 4 pinion gears (55) and 4 spherical
bly washers (54) to spider shaft (56).
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.
AJF00553
AJS00134
AJS00133
7) Install side gear (52).
AJS00130
AJS00132
30-104 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
2
match marks made when it was
removed. Mounting bolt:
3
98 - 123 Nm {10 - 12.5 kgm}
Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm} 2) Sling differential carrier assembly (43) and
set it to the mounting section of differential
AJS00129
9JF01496
3 Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
AJF01188
AJS00127
WA320-5H 30-105d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
AJF01191
3) Apply axle oil to the bearing. Using guide
bolt [16], install shims (87) and bearing carri-
mounting bolts.
3 Mounting bolt:
98 - 122.5 Nm {10- 12.5 kgm}
AJF01190
30-106 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
3 Mounting nut:
441 - 539 Nm {45 - 55 kgm}
9JF00865
9JF00866
WA320-5H 30-107d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
6. Assembly of rear cage assembly (For rear differ- 5) Remove coupling (41). Using tool H10,
ential) press fit oil seal (82).
2
1) Referring to 5 ASSEMBLY OF FRONT
Oil seal: Grease (G2-LI)
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 Mounting bolt:
245 - 309 Nm {25.0 - 31.5 kgm} 6) Install coupling (41).
3 Mounting bolt:
245 - 309 Nm {25.0 - 31.5 kgm}
3
• Starting torque at cage mounting hole A:
AJF00605
30-108 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
8. Installation of rear cage assembly (For rear dif- 2) If the measured backlash is out of the stan-
ferential) dard range, adjust it by moving a part of the
tightening torque, see 7 INSTALLATION part of shims (g) to the shims (f). (Move
OF FRONT CAGE ASSEMBLY. the bevel gear in direction A, or to the
AJF01194
9JF01500
9. Adjusting backlash
1) Measure the backlash of the bevel gear with
dial gauge [20].
AJF01195
CJH11993
WA320-5H 30-109d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
as follows.
• Middle of tooth height
• Point on tooth at which distance of
30-110 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
5) If the bevel gear is too far from the bevel pin- mer, etc. to press fit it. (If it is press fitted
ion, the tooth contact pattern is as follows. In so, it and its O-ring will be damaged.)
this case, adjust the tooth contact according
to the following procedure.
• Increase the shims of the cage assembly
(on the bevel pinion side) to move the
cage assembly in the direction (E).
• Adjust the shims on both sides of the
bearing carrier to move bevel gear in the
9JF00876
a Do not change the total thickness of the
direction of (F) close to the bevel pinion.
9JF00872
WA320-5H 30-111d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
3) Install bleeder screw (19). a Since tool [25] has the same appearance
as a disassembled slack adjuster, make a
a You may install tool [25] when checking
4) Install tool [25] (See the next step).
mark on it for distinction.
for brake oil leakage. 1) Keep installer [24] (equivalent to tool H11)
5) Set installer [24] (equivalent to tool H11). set.
k
Using tool H5, supply air into the brake oil
If the brake oil leakage test is per-
port to fit the piston.
formed without setting installer [24],
k
If the air is supplied without setting the piston will jump out, and that is
installer [24], the piston will jump dangerous.
out, and that is dangerous.
2) Install tool [25], adapter H14, plug H15, nip-
ple H16 and pump H13 to the brake port and
bleed all air from the brake system through
AJF01395
AJF01396
9JF01503
30-112 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
2
is measured, the pressure fluctuates.
Accordingly, do not move the hose. Threads: Gasket sealant (LG-5)
3
5) Remove pump H13, nipple H16, adapter
H14, plug H15, tool [25], and installer [24] Axle oil temperature sensor:
(equivalent to tool H11). 29.4 - 49 Nm {3 - 5 kgm}
3
14. Top cover
1) Install top cover (21). Mounting bolt:
98 - 122.5 Nm {10 - 12.5 kgm}
2) Install slack adjusters (22) to the right and
2
4) Install brake tube assembly (12).
3
Mating face of cover: Adhesive
(LOCTITE 515 or equivalent) Mounting bolt:
3
98 - 122.5 Nm {10 - 12.5 kgm}
Mounting bolt:
98 - 122.5 Nm {10 - 12.5 kgm}
AJF01199
AJF01391
WA320-5H 30-113d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF DIFFERENTIAL ASSEMBLY
down. 9JF01411
2) Using push tool [22], press fit shaft and bear-
ing assembly (91) to long cage (27).
3 Mounting bolt:
98 - 123 Nm {10 - 12.5 kgm}
2
bearing) is on the lower side.
Mounting bolt: Adhesive (LT-2)
3 Mounting bolt:
245 - 309 Nm {25.0 - 31.5 kgm}
9JF01501
AJS00112
3 Drain plug:
127.4 - 176.4 Nm {13 - 18 kgm}
30-114 WA320-5H
REMOVAL, INSTALLATION OF HST PUMP AND 4-GEAR PUMP
DISASSEMBLY AND ASSEMBLY ASSEMBLY
REMOVAL, INSTALLATION OF
• (3): Hose between charge valve port (P)
HST PUMP AND 4-GEAR and brake/fan pump
PUMP ASSEMBLY • (4): 2 HST filter hoses
REMOVAL
k
Stop the vehicle on a level place and set the
safety bar to the frame.
k
Lower the work equipment to the ground, AJF01345
stop the engine, apply the parking brake,
and put chocks under the tires.
k
Slowly loosen the oil filler cap of the hydrau-
lic tank to release the residual pressure in
the hydraulic tank.
k
Disconnect the cable from the negative (–) • (5): Steering pump suction tube
terminal of the battery.
• (6): HST pump port (G) hose
• (7): HST pump port (S) hose
• (8): Parking brake solenoid port (T) hose
1. Drain the hydraulic oil.
6 Hydraulic tank: 89 l
AJF01347
WA320-5H 30-115..d
REMOVAL, INSTALLATION OF HST PUMP AND 4-GEAR PUMP
DISASSEMBLY AND ASSEMBLY ASSEMBLY
• (14): HST motor M1 port (T2) hose 4. Sling HST pump and 4-gear pump assembly (22)
• (15): HST motor M2 port (T2) hose temporarily, and then remove its 5 mounting
• (16): Steering priority valve port (P) hose bolts and it. [*1]
4
• (17): Hose between work equipment pump
HST pump and 4-gear pump assem-
and cut-off valve port (P)
bly: 150 kg
• (18): Transfer clutch valve port (T) hose
• (19): Transfer lubrication hose
• (20): Transfer cooler inlet hose
AJF01350
AJF01348
AJF01349
30-116 WA320-5H
REMOVAL, INSTALLATION OF HST PUMP AND 4-GEAR PUMP
DISASSEMBLY AND ASSEMBLY ASSEMBLY
[*1]
3 Mounting bolt:
A: 245 - 309 Nm {25.0 - 31.5 kgm}
B: 98 - 123 Nm {10.0 - 12.5 kgm}
AJF01352
5 Hydraulic tank: 89 l
AJF01351
WA320-5H 30-117..d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF HST MOTOR 1 ASSEMBLY
REMOVAL, INSTALLATION OF
4. Disconnect port T1 hose (4) and port T2 hose
HST MOTOR 1 ASSEMBLY (5).
5. Disconnect port A hose (6) and port B hose (7).
REMOVAL
k
Stop the vehicle on a level place and set the
safety bar to the frame.
k
Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires. 9JF01401
k
Slowly loosen the oil filler cap of the hydrau-
lic tank to release the residual pressure in
the hydraulic tank.
k
Disconnect the cable from the negative (–)
terminal of the battery.
6. Support motor 1 assembly (8) with tool [1] placed
on the transmission jack and remove 4 motor 1
1. Drain the hydraulic oil. mounting bolts. [*1]
6 Hydraulic tank: 89 l
7. Supporting motor 1 assembly (8) with the hand,
lower the transmission jack gradually to remove
motor 1 assembly (8).
4
2. Disconnect front drive shaft (1) from the transfer
side. Motor 1 assembly: 65 kg
AJF01353
AJF01355
AJF01354
30-118 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF HST MOTOR 1 ASSEMBLY
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
5 Hydraulic tank: 89 l
WA320-5H 30-119d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF HST MOTOR 2 ASSEMBLY
REMOVAL, INSTALLATION OF
4. Disconnect port T1 block and hose (4) and port
HST MOTOR 2 ASSEMBLY T2 block and hose (5).
5. Disconnect port A hose (6) and port B hose (7).
REMOVAL
k
Stop the vehicle on a level place and set the
safety bar to the frame.
k
Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires. 9JF01402
k
Slowly loosen the oil filler cap of the hydrau-
lic tank to release the residual pressure in
the hydraulic tank.
k
Disconnect the cable from the negative (–)
terminal of the battery.
6. Support motor 2 assembly (8) with tool [1] placed
on the transmission jack and remove 4 motor 2
1. Drain the hydraulic oil. mounting bolts. [*1]
6 Hydraulic tank: 89 l
7. Supporting motor 2 assembly (8) with the hand,
lower the transmission jack gradually to remove
motor 2 assembly (8).
4
2. Disconnect front drive shaft (1) from the transfer
side. Motor 2 assembly: 70 kg
AJF01353
AJF01357
AJF01356
30-120 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF HST MOTOR 2 ASSEMBLY
INSTALLATION
• Carry out installation in the reverse order to
removal.
[*1]
5 Hydraulic tank: 89 l
WA320-5H 30-121d
REMOVAL, INSTALLATION OF WORK EQUIPMENT CONTROL
DISASSEMBLY AND ASSEMBLY VALVE ASSEMBLY
REMOVAL, INSTALLATION OF
a Mark all the hoses and tubes with tags to
3. Disconnect the following hoses and tubes. [*1]
WORK EQUIPMENT CONTROL
VALVE ASSEMBLY prevent mistakes in the mounting position
k
Stop the vehicle on a level place and, apply • (6): Port A1 hose
the parking brake, and put chocks under the • (7): Port B1 hose
tires. • (8): Port A2 tube
k
• (9): Port B2 tube
Support the boom securely.
• (40): Bucket DUMP PPC hose
k
• (41): Bucket TILT PPC hose
Stop the engine, and then slowly loosen the • (42): Boom LOWER PPC hose
oil filler cap of the hydraulic tank to release
• (43): Boom RAISE PPC hose
the residual pressure in the hydraulic tank.
• (44): Port P hose
k
Operate the work equipment control lever • (46), (47): Port T hoses
2 - 3 times to release the residual pressure
in the work equipment circuit.
AJF01175
a This is the view from the rear lower part of
the work equipment valve.
AJS00061
30-122 WA320-5H
REMOVAL, INSTALLATION OF WORK EQUIPMENT CONTROL
DISASSEMBLY AND ASSEMBLY VALVE ASSEMBLY
4
No. Connecting point Band color
Work equipment control valve assem-
(40) Bucket DUMP Blue
bly: 65 kg
(41) Bucket TILT Red
AJF01179
• Work equipment lever specification: 3-lever (If
equipped)
AJF01278
WA320-5H 30-123..d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY
REMOVAL, INSTALLATION OF
a Mark all the hoses and tubes with tags to
3. Disconnect the following hoses and tubes. [*1]
TRAVEL DAMPER VALVE
ASSEMBLY prevent mistakes in the mounting position
k
Stop the vehicle on a level place and, apply • (4): Port A hose
the parking brake, and put chocks under the • (5): Port B hose
tires. • (6): Port T hose
k
Disconnect the cable from the negative (–)
terminal of the battery.
k
Stop the engine, and then slowly loosen the
oil filler cap of the hydraulic tank to release
the residual pressure in the hydraulic tank.
k
AJF01180
Operate the work equipment control lever
2 - 3 times to release the residual pressure
in the work equipment circuit.
3 Mounting bolt:
13 ± 0.6 Nm {1.3 ± 0.06 kgm}
30-124 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF TRAVEL DAMPER VALVE ASSEMBLY
4
• Carry out installation in the reverse order to
Travel damper valve assembly: 25 kg removal.
AJF01182
WA320-5H 30-125d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF HYDRAULIC TANK ASSEMBLY
REMOVAL, INSTALLATION OF
5. Disconnect 7 hoses (6), (7), (8), (9), (10), (11),
HYDRAULIC TANK and (12) from the hydraulic tank. [*1]
ASSEMBLY
REMOVAL
k
Stop the vehicle on a level place and set the
safety bar to the frame.
AJF01358
k
Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k
Operate the work equipment control lever
2 - 3 times to release the residual pressure
in the work equipment circuit.
k
Slowly loosen the oil filler cap of the
hydraulic tank to release the residual 9JF01403
pressure in the hydraulic tank.
AJF00760
3. Remove tube (3) from the hydraulic oil filter.
4. Remove hydraulic oil filter cover mounting bolts
(4) and move hydraulic oil filter cover assembly
(5) and its hoses to under the operator's cab.
AJF00757
30-126 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF HYDRAULIC TANK ASSEMBLY
4 Hydraulic tank and ladder assembly: • Carry out installation in the reverse order to
160 kg (including hydraulic oil) removal.
[*1]
WA320-5H 30-127d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY
REMOVAL, INSTALLATION OF
WORK EQUIPMENT
ASSEMBLY
REMOVAL
CEW02153
k
Stop the vehicle on a level place and set the
safety bar to the frame.
k
Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k
Disconnect the cable from the negative (-) 3. Move the machine to the rear and disconnect the
terminal of the battery. bucket.
4. Sling bucket cylinder assembly (3) temporarily
and pull out rod-side pin (4) to disconnect the cyl-
shims.
AJF01022
AJF01021
k
Never insert your fingers in the pin holes.
30-128 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY
5. Set supports [2] under the end of the lift arm and 7. Disconnect boom positioner proximity switch
release the residual pressure in the hydraulic connector F04 (7).
piping. 8. Remove boom kick-out switch (8). [*5]
CJW11351 AJF01370
4
10. Lift off lift arm and tilt lever and bucket link
Lift cylinder assembly (1 pieces): assembly (10).
4
110 kg
Lift arm and tilt lever and bucket link
assembly: 1250 kg
DBW01810
CJW11354
WA320-5H 30-129d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY
11. Sling bucket link assembly (12) temporarily, pull 14. Pull dust seal (17) and bushing (18) out of lift arm
out mounting pin (13), and remove the bucket (16). [*9]
link assembly from the tilt lever assembly. [*7]
CJW11357
CJW11355
15. Pull dust seal (19) and bushing (20) out of tilt
lever (14). [*9]
CJW11356 16. Pull dust seal (21) and bushing (22) out of bucket
link (12). [*9]
CJW11359
30-130 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY
k
or equivalent) or Hyper White
When aligning the pin holes, use a bar. (G1-T)
Never insert your fingers in the pin holes.
k
aligning the holes for mounting pin (1).
Never insert your fingers in the pin holes.
2. Insert shims on both sides so that clearances (a)
k
Never insert your fingers in the pin holes. the inside of the bushing and the seal.
WA320-5H 30-131d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY
[*3] 2. Install mounting pin (5) and lock it with bolt (28).
Procedure for installing bucket cylinder pin (on
k
rod side) Never insert your fingers in the pin holes.
1. Insert a shim in clearance (c).
a Take care not to damage the pin and seal.
• Clearance (c) (On each side): Max. 1.5 mm
a Before installing the pin, apply lubricant to
• Varieties of shim thickness: 1.5, 3.0 mm
2. Install mounting pin (4) and lock it with bolt (27). the inside of the bushing and the seal.
2
k
Never insert your fingers in the pin holes. Inside of bushing and seal:
Lubricant containing molybde-
a Take care not to damage the pin and seal.
num disulfide (LM-P or equiva-
the inside of the bushing and the seal. a After installing the pin, supply lubricant.
9JF01056 9JF01418
k
When starting the engine, check that the
forward-reverse lever is in neutral and the
parking brake is applied.
30-132 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY
2
1. Insert a shim in clearance (e).
Inside of bushing and seal:
• Clearance (e) (On each side): Max. 1.5 mm
Lubricant containing molybde-
• Varieties of shim thickness: 1.5, 3.0 mm
num disulfide (LM-P or equiva-
2. Install mounting pin (11) and lock it with bolt (29). lent) or Hyper White (G2-T)
2
a Take care not to damage the pin and seal.
Lubricant: Lubricant containing
[*8]
9JF01058 1. Install the mounting pin and lock with the bolt.
k
Never insert your fingers in the pin holes.
2
[*7]
Inside of bushing and seal:
a It is not necessary to insert a shim in clearance
Procedure for installing bucket link pin
Lubricant containing molybde-
num disulfide (LM-P or equiva-
wires, etc.
1. Install cord ring (30), aligning the holes for
bucket link mounting pin (13).
2. Install mounting pin (13) and lock it with bolt (31).
k
Never insert your fingers in the pin holes.
WA320-5H 30-133d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF WORK EQUIPMENT ASSEMBLY
9JF01060
9JF01463
30-134 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
DISASSEMBLY AND
2. Low pressure valve assembly.
ASSEMBLY OF HST PUMP
a Do not change adjustment screw.
1) Remove low pressure valve assembly (2).
ASSEMBLY
SPECIAL TOOLS LIST
Sym- Part Neces New/
Part No. Q'ty Sketch
bol name sity Remodel
K1 790-201-2720 Push tool q 1
790-201-2730 Push tool t 1
t
K2 CJW11903
790-201-2830 Push tool 1
K3 790-201-2740 Push tool q 1
DISASSEMBLY
a If the pump body is disassembled, the assembly
a General view
special tool will be required. See ASSEMBLY 3. 5). 2) Disassemble the low pressure relief valve
according to the following procedure, if nec-
CJW11902
WA320-5H 30-135d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
CJW11906
CJW11905
30-136 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
CJW11909
CJW12132
CJW11910
WA320-5H 30-137d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
6. Charge pump assembly (44) 3) Mark position of the port plate, m1.
1) Remove the 4 mounting bolts (97) and 4) Loosen port plate fixation.
charge pump assembly (44).
2) Remove wear plate (43).
3) Remove gear (46).
flange (45).
CJW12134
CJW12131
5) Lift off port plate Assembly (51) and control
plate (52).
CJW11918
CJW12133
30-138 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
CJW11920
CJW11921
WA320-5H 30-139d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
i) Remove the assembly of pistons (57) v) Remove snap ring (63) from the cylinder
and retainer (58) from cylinder block block.
k
(56).
ii) Remove 9 pistons (57) from retainer Snap ring (63) will jump out. Take care.
(58).
vi) Remove spring (62) and 2 shims (65).
a Check of pistons
• Check that there are no scratches or
metal deposits on sliding surface (b),
and there is no axial play (c), (otherwise:
CJW11922 pistons must be replaced in sets).
CJW11926
30-140 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
ellipse) together.
CJW11930
CJW12145
CJW11931
CJW11928
CJW11929
CJW11932
WA320-5H 30-141d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
11. Swivel cradle (73), Bearing cups (74) • Bearing surfaces ( j ) of cradle (76).
1) Remove swivel cradle (73).
a Check
2) Remove bearing cups (74).
CJW11934
CJW12135
CJW12140
CJW12154
CJW12136
CJW11935
30-142 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
3) Mark position m2, m3 of the cover (80), (81), 7) Remove servo piston assembly (82).
note measure of "zero position" ( k ) .
4) Loosen nut (79).
CJW12138
CJW12137
a Check of groove A.
CJW11943
WA320-5H 30-143d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
CJW11948
CJW12139
CJW12146
30-144 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
a The deformation of the seal has to v) Using tool K1, push collar (83).
be done withcare so as not to dam- vi) Install snap ring (85).
age the sealing edges. vii) Install ring (84).
pan.
1) Dip piston (90), rod (91), springs (87) and
(88), collars (83) and (89) in engine oil
(EO10-CD).
CJW12152
2) Assemble the servo piston assembly accord-
ing to the following procedure.
i) Install rod (91) to piston (90).
WA320-5H 30-145d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
CJW12143
CJW11957
CJW12154 CJW11954
CJW12144
30-146 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
CJW11958
CJW11959
WA320-5H 30-147d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
CJW12151
CJW12150
CJW11963
CJW11928
CJW11964
30-148 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
CJW11921
WA320-5H 30-149d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
retaining device.
CJW12142
CJW11966
3) Assembly aid:
Hold the cylinder block and piston Assembly
(54) by using an O-ring (96).
CJW11967
v) Install 9 pistons (57) to retainer (58).
vi) Install piston and retainer assembly to
30-150 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
CJW11971
CJW12141
CJW11969
7. Port plate (51)
1) Assemble port plate (51), matching m1.
k
Spring preloaded!
CJW12134
CJW12149
WA320-5H 30-151d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
3) Locking screw (50) - Observe adjusting mea- 9. Charge pump assembly (44)
sure, the angle m0. 1) Install wear plate (43)
flange (45).
3) Install gear (46) to flange (45).
4) Install charge pump assembly (44) with the 4
mounting bolts (97).
CJW12148
CJW12131
8. Servo piston cover
1) Install servo piston covers (80) and (81) to
oil.
CJW11975
30-152 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
10. Forward-reverse solenoid valve (34) 2) Install 2 solenoid valves (36) to the valve
2 Threads of plug:
ThreeBond No. 1305
CJW11909
WA320-5H 30-153d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
CJW11906
CJW11907
CJW11905
30-154 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
13. Low pressure relief valve assembly 14. High pressure relief valve assembly
1) Assemble the low pressure relief valve Fit the O-ring and install 2 high pressure relief
assembly according to the following proce- valve assemblies (1).
3
dure.
i) Install adjustment screw (7) to holder (8). High pressure relief valve assem-
bly:
ii) Install the locknut (6).
200 ± 10 Nm {20.39 ± 1.02 kgm}
iii) Install piston (5).
iv) Install spring seat (4) and spring (3) to
the pump case.
CJW11902
CJW11904
CJW11903
WA320-5H 30-155d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
k
Adjustments of the correct zero position
to be carried out after installation into the
machine or on the bench test.
CJW12162
CJW12137
30-156 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
WA320-5H 30-157d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
(2) Plugs
i) Plugs with internal hexagon and profile
seal ring
CJW11977
M27 x 2 90 9.18
30-158 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
CJW11977
3/4-16UNF 72 7.34
WA320-5H 30-159d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
CJW11978
Tightening torque
Thead
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
30-160 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST PUMP ASSEMBLY
CJW12038
10.9 11.9
Thead
Tightening torque
Nm kgm Nm kgm
WA320-5H 30-161d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
DISASSEMBLY AND
2. EP servo valve assembly and cover (HST
ASSEMBLY OF HST MOTOR motor 1)
ASSEMBLY
SPECIAL TOOLS LIST
Sym- Part Neces New/
Part No. Q'ty Sketch
bol name sity Remodel
M1 02010-21057 Bolt q 1 CJW12101
790-201-2740 Push tool t 1
M2 793T-417-1120 Push tool q 1
02010-21057 Bolt q 1
DISASSEMBLY
1. Seal
1) Protecting the driver shaft by tape.
2) Remove snap ring (2) and shim (3).
CJW11980
CJW11982
CJW11981
30-162 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
CJW11987
CJW11983
CJW12104
CJW12163
a
iii) Remove pin (20)
Do not remove nut (21) and screw 22.
a
iv) Remove plugs (24) from housing (13).
Do not remove plug (23).
CJW12103
WA320-5H 30-163d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
1) Remove the 4 mounting bolts and solenoid 4) Disassemble 2 solenoids and housing
valve and housing assembly (27) from port assembly (27).
CJW12105 CJW12106
CJW12125
CJW12108
30-164 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
CJW12107
CJW12112
WA320-5H 30-165d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
CJW12164
30-166 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
CJW12165
WA320-5H 30-167d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
7) Make match marks (c) between port plate (6) a Check of port plate
and housing (82). • Sliding surface and side guides free of
8) Remove port plate assembly (6). scoring and no wear.
CJW12115 CJW12002
5. Disassemble the port plate (6) assembly accord- a Check of control plate
ing to the following procedure. Faces smooth and even, free of cracks and
i) Remove control lens (80). scoring.
ton (69).
CJW12039
CJW12113
CJW12119 CJW12127
30-168 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
k
If the bearings are used again do not
hit on the drive shaft.
CJW12008
CJW12005
a If a press is not available, push the shaft end 7. Disassembly of rotary group assembly (70)
with tool [3] or [4] to remove rotary group 1) Remove screw [2].
assembly (81).
2) Remove cylinder block (83).
CJW12006 CJW12009
CJW12007
CJW12011
WA320-5H 30-169d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
CJW12014
CJW12010
CJW12116
CJW12128
CJW12013
30-170 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
CJW12128
CJW12121
CJW12021
CJW12024
WA320-5H 30-171d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
2) Insert the shaft and rotary group assembly 3. Port plate (6) assembly
(81) into housing (82) to seat position. 1) Assemble the port plate (6) assembly
according to the following procedure.
i) Install valve seat (79).
ii) Install poppet (78).
iii) Install valve guide (77).
CJW12117
CJW12119
CJW12118
CJW12113
30-172 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
CJW12122
CJW12115
torque.
WA320-5H 30-173d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
3 Guide (64): 8 Nm {0.81 kgm} v) Install snap ring (58), orifice (57),
plunger (56), and spring (55).
ii) Install plug (63). vi) Install plug (54).
3 Plug: 3 Plug: 50 Nm {5.1 kgm}
29 - 38 Nm {2.96 - 3.89 kgm}
CJW12164
30-174 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
3
caps (37) and (36) of the solenoid in
Plug: order.
55 - 60 Nm {5.61 - 6.12 kgm}
CJW12106
CJW12112
(35).
CJW12108
WA320-5H 30-175d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
6) Install solenoid valve and housing assembly 2) Assemble the housing assembly (5) accord-
(27) with the 4 mounting bolts to port plate ing to the following procedure.
(6). i) Install plug (24) to housing (13).
ii) Install pin (20).
iii) Install bushing (19) and spool (18) to
(13).
CJW12105
CJW12103
3 Plug: 29 - 38 Nm {3.0 - 3.9 kgm} iv) Install snap ring (16), coil (15), and cap
(14) in order to housing assembly (13).
ii) Install cover (25).
3 Mounting bolt:
39 - 49 Nm {4.0 - 5.0 kgm}
CJW12102
CJW11987
30-176 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY OF HST MOTOR ASSEMBLY
3) Install spring (10) and spring seat (11) to port 5) Install snap ring (2).
plate (6).
4) Install spring (12) and spring seat (9).
5) Install spring (8) and spring seat (7).
CJW11980
CJW11983
CJW12036
CJW11982
WA320-5H 30-177d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
DISASSEMBLY, ASSEMBLY
OF HYDRAULIC CYLINDER
ASSEMBLY
SPECIAL TOOLS DISASSEMBLY
1. Cylinder assembly
Set cylinder assembly (1) to tool U1.
New/Remodel
Necessity
Sketch
2. Cylinder head and piston rod assembly (Steering
Q'ty
Symbol Part No. Part Name
cylinder)
1) Using tool U2, remove cylinder head (2) from
790-502-1003 Repair stand t 1 the cylinder.
t
1
790-101-1102 Hydraulic pump 1
t
790-102-2303
2 or Wrench assembly
1
(for steering)
790-102-3802
01010-50816 • Bolt 1
• Push tool
790-201-1831 1
(bucket)
• Push tool
790-201-1741 1
(steering)
t
2) Pull cylinder head and piston rod assembly
01010-50816 • Bolt 1
assembly is pulled out of the cylinder,
prepare an oil receiver.
5 790-201-1630 • Plate (boom) 1
• Push tool
790-201-1550 1
(steering)
6 790-720-1000 Expander q 1
q
Ring
796-720-1680 1
(boom and bucket) 9JF01062
q
Ring
07281-01589 1
7 (boom and bucket)
t
Wrench assembly
790-102-4300 (for boom and 1
8 bucket)
790-102-4310 Pin t 2
30-178 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
3. Cylinder head and piston rod assembly (Bucket 4. Piston and cylinder head (Steering cylinder)
cylinder and boom cylinder) 1) Set cylinder head and piston rod assembly
1) Remove the mounting bolt of cylinder head (3) to tool U1.
assembly (2). 2) Using tool U3, remove nut (5).
• Width across flats of bolt: 24 mm • Width across flats of nut (Steering):
46 mm
3) Remove piston assembly (6) and cylinder
head assembly (2).
9JF01063
9JF01065
9JF01064
WA320-5H 30-179d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
5. Piston and cylinder head (Bucket cylinder and 6. Disassembly of piston assembly
boom cylinder) 1) Remove wear ring (9) and piston ring (10)
1) Set cylinder head and piston rod assembly from piston (8).
(3) to tool U1.
2) Remove lock screw (18) of the piston
9JF01406
9JF01078
30-180 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
a Steering cylinder
9JF01407
9JF01407
9JF01408
WA320-5H 30-181d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
3 Nut (Steering):
785 ± 78.5 Nm {80 ± 8.0 kgm}
9JF01065
9JF01074
30-182 WA320-5H
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
10.3 27 12 X 1.75 20
3 Lock screw:
58.9 - 73.6 Nm {6 - 7.5 kgm} 3) Using tool U2, install cylinder head assembly
(2) to the cylinder.
3 Cylinder head:
539 ± 54.0 Nm {55 ± 5.5 kgm}
9JF01409
CED00174
9JF01078
WA320-5H 30-183d
DISASSEMBLY AND ASSEMBLY DISASSEMBLY, ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
9JF01064
9JF01410
30-184 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY
REMOVAL, INSTALLATION OF
1. Remove right and left fenders (1), right and left
OPERATOR'S CAB brackets (2), and left inspection cover (3).
ASSEMBLY
SPECIAL TOOLS
New/Remodel
AJF01282
Necessity
Sketch
Q'ty
Symbol Part No. Part Name
t
Vacuum pump
799-703-1100 (100 V)
1
t
Vacuum pump
X 1 799-703-1110
(220 V)
1 2. Remove covers (4) and (5) from the right and left
t
operator's cab.
Vacuum pump
799-703-1120 1
(240 V)
REMOVAL
k
Stop the vehicle on a level place and set the AJF01283
safety bar to the frame.
k
Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k
Operate the work equipment control lever
k
2 - 3 times to release the residual pressure
in the work equipment circuit. Keep in mind that you cannot apply the
k
parking brake (the parking brake is
Slowly loosen the oil filler cap of the hydrau- released).
lic tank to release the residual pressure in
the hydraulic tank. 3. Turn the parking brake OFF (Release it).
k
4. Remove cotter pin (52) and pin (53) from the
Connect tool X1 to the air conditioner com- parking brake connecting part.
pressor hose valve and collect the refriger-
a These cotter pin and pin are at the front part
(Part (51) is the transfer oil cooler.) [*5]
ant (R134a).
k
Disconnect the cable from the negative (–) of inside of the left rear wheel.
terminal of the battery.
AJF01388
WA320-5H 30-185d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY
5. Measure the installed height of the parking brake 10. Disconnect cab ground wire (9) from the right
wire up to locknut (56). side of the operator's cab.
6. Loosen locknut (56) and disconnect parking
brake wire (54) from parking brake bracket (55).
a Right side of operator's cab
11. Disconnect the following wiring connectors.
[*6]
• (10): FL1
• (11): FL2
• (60): FL3 (Emergency steering: If equipped)
• (61): FL4 (Far side)
9JF01465
AJF01281
AJF01279
30-186 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY
12. Disconnect wire clamp (23) and brake valve 15. Disconnect wire clamp (67).
hose clamp (24).
AJF01289
AJF01284
AJF01287
AJF00696
WA320-5H 30-187d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY
18. Disconnect hoses (25) - (29) from the orbit-roll a The band colors of PPC hoses (32) - (37)
valve. and hoses T and P are as follows.
• (25): Port LS hose (Right) 1) Work equipment control lever specification:
• (26): Port P hose (Left lower) 2-lever
• (27): Port R hose (Right lower) 2) Work equipment control lever specification:
3-lever (If equipped)
• (28): Port T hose (Left upper)
• (29): Port L hose (Right upper) No. Connecting point Band color
AJF01288
AJF01290
q37 q36
qT => Front of chassis
q35 q34
qP
q33 q32
30-188 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY
3 Ports P, R, T, and L:
53.9 - 73.5 Nm {5.5 - 7. 5 kgm}
[*4]
to 180 degrees.
[*6]
WA320-5H 30-189d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF OPERATOR'S CAB ASSEMBLY
5 Hydraulic tank: 89 l
30-190 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS
REMOVAL, INSTALLATION OF
OPERATOR'S CAB GLASS
(STUCK GLASS)
SPECIAL TOOLS
CPW11602
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part Name
t
a The broken window glass may be removed
2 2 793-498-1130 Plate 2
t
X
3 793-498-1110 Magnet 2
CPW11601
2. Remove the window glass.
WA320-5H 30-191d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS
INSTALLATION
1. Using scraper [5], remove the remaining adhe-
CPW11605
CPW11603
CPW11604
30-192 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS
a When sticking the both-sided adhesive tape 3) Using tool X3 (suction cups), place window
around a side or a rear window glass, start at glass (3) on tool X2-1 (5 mm spacer) and
center of the top and make a clearance of match it to the operator's cab.
about 5 mm at end joint (c).
CPW11615
CWW11608
CPW11613
CPW11616
WA320-5H 30-193d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS
CWW11624
CPW11609
2
(If it is applied more than 2 times, its per-
Paint primer: SUNSTAR PAINT
a Parts to be coated with primer: Apply the
formance will be lowered.)
PRIMER 580 SUPRE
a Do not apply the primer more than 2 primer to the sticking surface of window
times. glass (3) and all over dimension (d) on
(If it is applied more than 2 times, its per- both-sided adhesive tape (4) and opera-
tor's cab (2).
a Parts to be coated with primer: Apply the
formance will be lowered.)
• Dimension to apply primer (d):
wipe it off with white gasoline. wipe it off with white gasoline.
(If wrong primer is applied, the glass will (If wrong primer is applied, the glass will
not be stuck.) not be stuck.)
30-194 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS
CWW11625
CPW11612
2 Adhesive (Summer):
SUNSTAR PENGUINE SEAL
580 SUPER "S"
2 Adhesive (Winter):
SUNSTAR PENGUINE SEAL
580 SUPER "W"
3) Set adhesive cartridge (9) to caulking gun
a The using limit of the adhesive is 4 months
a An electric caulking gun is more efficient.
[7].
after the date of manufacture. Do not use
WA320-5H 30-195d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS
CWW11620
CPW11621
CPW11619
CPW11614
30-196 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS
CPW11622
10. If the front glass and both front glasses are
replaced, seal them.
1) Stick masking tapes (14) along the parts to
CPW11628
CWW11626
strongly.
CPW11623
WA320-5H 30-197d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF OPERATOR'S CAB GLASS
2) Fill the joint of the glasses with caulking 3) Remove the caulking material projected from
CPW11631
4) Remove the masking tapes from the window
glass.
11. Remove the primer and adhesive from the oper-
impact to it.
COATING MATERIALS
Komatsu
Category Part No. Q’ty Container Main applications, featuresr
code
SUNSTAR,
PAINT Glass
PRIMER 580 20 ml container
• Used as primer for cab. (Using limit: 4 months)
SUPER
Primer
SUNSTAR,
GLASS 20 ml Glass • Used as primer for cab. (Using limit: 4 months)
PRIMER 580 417-926-3910 container
SUPER
For sticking cab glass
SUNSTAR,
PENGUINE • "S" and "W" are used as adhesive for glass at high tem-
Polyethylene
SEAL 580 320 ml perature (summer) and low temperature (winter) respec-
container
SUPER "S" or tively. (Using limit: 4 months)
Adhesive "W"
SIKA JAPAN,
Polyethylene
SIKAFLEX 256 20Y-54-39850 310 ml • Used as adhesive for glass. (Using limit: 6 months)
HV container
SUNSTAR,
PENGUINE 417-926-3920 320 ml Polyethylene • Used to seal joint of glasses (Using limit: 4 months)
SEAL NO. container
Caulking 2605
material
SEKISUI SILI-
CONE SEAL- 20Y-54-55130 333 ml Polyethylene • Used to seal front window (Using limit: 6 months)
container
ANT
30-198 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CENTER HINGE PIN
REMOVAL, INSTALLATION OF
2. Set the work horizontally, place blocks [1] under
CENTER HINGE PIN both sides of the rear frame, raise the counter-
weight with hydraulic jack [2], and set stands [3].
SPECIAL TOOLS
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part Name
• 790-101-5221 • Grip 1
Y • 01010-51225 • Bolt 1
REMOVAL
k
Stop the vehicle on a level place and set the
safety bar to the frame. AJF00732
k
Lower the work equipment to the ground,
stop the engine, apply the parking brake,
and put chocks under the tires.
k
Disconnect the cable from the negative (–)
terminal of the battery.
AJS00061
AJS00059
WA320-5H 30-199d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CENTER HINGE PIN
5. Disconnect all wiring harness clamps (3) 7. Disconnect front drive shaft (5). [*2]
between the front frame and rear frame from the
AJF01161
AJF01163
AJF01162
AJS00064
30-200 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CENTER HINGE PIN
9. Remove brake hose clamp (8). 12. Remove pins (11) and hoses (9) and (10) from
10. Disconnect PPC hoses (40) - (43) from the work the bottom side of the right and left steering cylin-
equipment valve. [*3] ders, and then disconnect the right and left steer-
AJF01167
AJF01165
AJF01164
AJF01166
AJF01177
WA320-5H 30-201d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CENTER HINGE PIN
14. Remove the upper hinge pin. [*6] 15. Disconnect the front frame and rear frame. [*8]
1) Remove mounting bolt (14). 1) Set hand lift truck [4] under bucket (19).
AJF01168 AJF00736
2) Remove the mounting bolts, cover (15), and 2) Using a bar, etc., raise front frame assembly
AJF01169
9JF00909
AJF01170
30-202 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CENTER HINGE PIN
AJF00737
AJF00740
AJF00739
9JF01428
WA320-5H 30-203d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CENTER HINGE PIN
30-204 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CENTER HINGE PIN
• Work equipment lever specification: 3-lever 2. Assemble the upper hinge of the front frame.
(If equipped) 1) Using push tool [Y3], press fit bearing (33a)
2
9JF01425
Inside of bushing on cylinder side and
dust seal: Lubricant containing molyb-
denum disulfide (LM-P)
2
rear frame.
Lip of dust seal: Grease (G2-LI)
AJF00741
WA320-5H 30-205d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CENTER HINGE PIN
3 Mounting bolt:
98 - 123 Nm {10.0 - 12.5 kgm}
9JF00913
9JF01434
9JF01431
9JF01426
30-206 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CENTER HINGE PIN
2
and then select shims so that the maximum
Lip of dust seal: Grease (G2-LI) clearance will be less than 0.1 mm when the
shims are inserted.
• Standard shim thickness: 1 mm
• Varieties of shim thickness:
3 Mounting bolt:
98 - 123 Nm {10.0 - 12.5 kgm}
3
ever.)
Retainer mounting bolt:
19.6 ± 10% Nm {2 ± 10% kgm}
AJF00747
WA320-5H 30-207d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CENTER HINGE PIN
2
toward the rear frame.
Upper spacer: Lubricant con-
taining molybdenum disulfide
(LM-P)
AJF00737
AJF01173
2 - 3 mm with a large-sized crane, if avail- 6. Secure cover (15) of upper hinge pin (16) with
pin.
2 Mounting bolt:
Adhesive (LOCTITE #2701)
3 Mounting bolt:
9JF00909 186 - 226 Nm {19 - 23 kgm}
k
When aligning the pin holes, use a bar.
Never insert your fingers in the pin holes.
AJF01172
30-208 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF CENTER HINGE PIN
8. Insert selected shim (17) between cover (15) and 10. Install mounting bolt (14) of upper hinge pin (16).
the rear frame and tighten the 6 mounting bolts.
2 Mounting bolt:
Adhesive (LOCTITE #2701)
3 Mounting bolt:
98 - 123 Nm {10.0 - 12.5 kgm}
AJF01168
9. Install lock bolt (12) of lower hinge pin (13).
9JF00917
WA320-5H 30-209d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF COUNTERWEIGHT
REMOVAL, INSTALLATION OF
8. Open the engine left side cover and disconnect
COUNTERWEIGHT wiring connector BR1 (8).
REMOVAL
k
Stop the vehicle on a level place and set the
safety bar to the frame.
k
Lower the work equipment to the ground,
AJF01275
stop the engine, apply the parking brake,
and put chocks under the tires.
AJF01273 AJF01276
AJF01274
30-210 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF COUNTERWEIGHT
4
[*1]
3
Counterweight and batteries (both)
assembly: 2,020 kg Mounting bolt:
824 - 1030 Nm {84 - 105 kgm}
[*2]
WA320-5H 30-211d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
REMOVAL, INSTALLATION OF
a Disconnect the heater hoses from the air
2. Disconnect 2 heater hoses (24) from tube (23).
AIR CONDITIONER UNIT
ASSEMBLY conditioner unit.
SPECIAL TOOLS
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part Name
AJS00066
799-703-1200 Service tool kit t 2
t
Vacuum pump
799-703-1100 (100 V)
1
t
Vacuum pump
X 1 799-703-1110 (220 V) 1
t
Vacuum pump
799-703-1120 1
(240 V)
799-703-1400 Gas leak tester t 1 3. Remove covers (1), (2), and (3).
REMOVAL
k
Stop the vehicle on a level place and set the
safety bar to the frame.
k
Lower the work equipment to the ground, AJS00068
stop the engine, apply the parking brake,
and put chocks under the tires.
k
Disconnect the cable from the negative (–)
terminal of the battery.
k
Connect tool X1 to the air conditioner com-
pressor hose valve and collect the refriger-
ant (R134a).
AJS00067
30-212 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
a If equipped: Load meter specification 5. Remove brackets (31), (5), and (32) and cover
to strain them.
2) Remove the 4 bolts at the bottom of cover
(25) and disconnect load meter unit (26) and
cover (25). AJS00071
3) Disconnect connectors (28) and (29) from
the rear of load meter unit (26).
4) Remove bracket (30).
AJS00072
AJS00070
WA320-5H 30-213d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
8. Remove wiring connectors L53 (8) and L47 (9). 13. Disconnect air conditioner pipes (14) and (15).
9. Remove box (10). [*1]
AJF00921 AJF00924
10. Remove wiring connector bracket (10). 14. Remove the mounting bolts and air conditioner
unit assembly (16).
11. Disconnect clamp (11).
AJF00925
AJF00922
INSTALLATION
12. Disconnect wiring connectors A03 (11), A01
(12), and A02 (13). • Carry out installation in the reverse order to
removal.
[*1]
2 O-ring:
Compressor oil for new refrigerant
(NO-OIL8)
AJF00923
30-214 WA320-5H
REMOVAL, INSTALLATION OF AIR CONDITIONER COMPRESSOR
DISASSEMBLY AND ASSEMBLY ASSEMBLY
REMOVAL, INSTALLATION OF
9. Remove 2 mounting bolts (7), 2 mounting bolts
AIR CONDITIONER (8), and air conditioner compressor bracket
COMPRESSOR ASSEMBLY assembly (12).
SPECIAL TOOLS
New/Remodel
Necessity
Sketch
Q'ty
Symbol Part No. Part Name
AJF00926
799-703-1200 Service tool kit t 2
t
Vacuum pump
799-703-1100 (100 V)
1
t
Vacuum pump
X 1 799-703-1110 (220 V) 1
t
Vacuum pump
799-703-1120 1
(240 V)
REMOVAL
k
Lower the work equipment to the ground,
stop the engine, apply the parking brake, AJF00927
and put chocks under the tires.
k
Disconnect the cable from the negative (-)
terminal of the battery.
k
Connect tool X to the air conditioner com-
pressor hose valve and collect the refriger-
ant (R134a).
INSTALLATION
• Carry out installation in the reverse order to
1. Open the engine left side cover.
removal.
2
terminal E22 (2).
O-ring:
Compressor oil for new refrigerant
3. Disconnect air conditioner pipes (3) and (4). [*1]
(NO-OIL8)
WA320-5H 30-215..d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF MONITOR PANEL
REMOVAL, INSTALLATION OF
3. Remove steering wheel mounting nut (3). [*1]
MONITOR PANEL
REMOVAL
k
Disconnect the cable from the negative (–)
terminal of the battery.
1. Remove pad (1) from the steering wheel. 4. Using puller [1], remove steering wheel (4) from
the steering column.
AJF00762
AJF00765
AJF00763
AJF00766
30-216 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF MONITOR PANEL
AJF00769
AJS00074
AJS00075
9JF00920
WA320-5H 30-217d
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF MONITOR PANEL
9. Remove monitor panel and bracket assembly a Load meter specification (If equipped)
(22) according to the following procedure.
to strain them.
AJS00076
AJS00079
a Standard
2) Disconnect monitor panel wiring connectors
L21 (21), L22 (22), and L23 (23) from the
AJF00772
AJS00080
30-218 WA320-5H
DISASSEMBLY AND ASSEMBLY REMOVAL, INSTALLATION OF MONITOR PANEL
[*2]
[*3]
3 Crossed screw:
a Correspondence table of wiring connectors 4.9 - 7.84 Nm {0.5 - 0.8 kgm}
AJS00081
AJS00077
[*4]
[*5]
WA320-5H 30-219d
white 30-220
OTHERS
90 OTHERS
WA320-5 90-1
HYDRAULIC CIRCUIT DIAGRAM
WA320-5 90-3
ELECTRICAL CIRCUIT DIAGRAM 1/5 (1/4)
(Machines equipped with speed meter)
WA320-5 90-5
ELECTRICAL CIRCUIT DIAGRAM 1/5 (2/4)
(Machines equipped with speed meter)
WA320-5 90-7
ELECTRICAL CIRCUIT DIAGRAM 1/5 (3/4)
(Machines equipped with speed meter)
WA320-5 90-9
ELECTRICAL CIRCUIT DIAGRAM 1/5 (4/4)
(Machines equipped with speed meter)
WA320-5 90-11
ELECTRICAL CIRCUIT DIAGRAM 2/5 (1/4)
(Machines equipped with load meter)
WA320-5 90-13
ELECTRICAL CIRCUIT DIAGRAM 2/5 (2/4)
(Machines equipped with load meter)
WA320-5 90-15
ELECTRICAL CIRCUIT DIAGRAM 2/5 (3/4)
(Machines equipped with load meter)
WA320-5 90-17
ELECTRICAL CIRCUIT DIAGRAM 2/5 (4/4)
(Machines equipped with load meter)
WA320-5 90-19
ELECTRICAL CIRCUIT DIAGRAM 3/5
WA320-5 90-21
ELECTRICAL CIRCUIT DIAGRAM 4/5
WA320-5 90-23
ELECTRICAL CIRCUIT DIAGRAM 5/5
WA320-5 90-25