SEBM034600

Shop
Manual

WA320L-5
WHEEL LOADER
SERIAL NUMBERS WA320L-5 60001 and up
This material is proprietary to Komatsu America Corp. and is not to be reproduced, used, or disclosed except in
accordance with written authorization from Komatsu America Corp..

It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to
make changes or improvements at any time without incurring any obligation to install such changes on products
sold previously.

Due to this continuous program of research and development, revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.

Copyright 2003 Komatsu

Printed in U.S.A.
Komatsu America Corp.
October 2003
 CONTENTS

No. of page
01 GENERAL ......................................................................................... 01-1

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ...... 10-1

20 TESTING AND ADJUSTMENT....................................Will be issued later

30 DISASSEMBLY AND ASSEMBLY ..............................Will be issued later

90 OTHERS ............................................................................................ 90-1

00-2 WA320-5
SAFETY SAFETY NOTICE

SAFETY
SAFETY NOTICE

IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.

To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
• Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
• Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.

00-3
SAFETY SAFETY NOTICE

PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.

00-4
FOREWORD GENERAL

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.

This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.

STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.

TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.

DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.

MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.

OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

NOTICE

The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.

00-5
FOREWORD HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

VOLUMES When a manual is revised, an edition mark

Shop manuals are issued as a guide to carrying out ((1)(2)(3)....) is recorded on the bottom of the pages.
repairs. They are divided as follows:

Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series

}
Each issued as one Revised pages are shown in the LIST OF REVISED
Electrical volume: PAGES next to the CONTENTS page.
Attachments volume: volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.

DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks

k
date information before you start any work.
Special safety precautions
Safety are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order. tions or other precautions
2. Following examples show how to read the page a Caution for preserving standards
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3
4
tems. Caution necessary
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
3
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):

2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine)
5
Places where oil, water or
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
6
item. Places where oil or water
Drain m u s t b e d r a i n ed , a n d
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204

00-6
FOREWORD HOISTING INSTRUCTIONS

HOISTING INSTRUCTIONS

HOISTING

Slinging near the edge of the hook may cause

k Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting, and
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol 4

• If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing 3) Do not sling a heavy load with one rope alone,
interference with the part to be removed. but sling with two or more ropes symmetrically
wound onto the load.
k Slinging with one rope may cause turning
WIRE ROPES
1) Use adequate ropes depending on the of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to the rope, or slipping of the rope from its
the table below: original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120° hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150°.

a The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.

2) Sling wire ropes from the middle portion of the

hook.

00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

k Before carrying out the following work, release Type 1

the residual pressure from the hydraulic tank.
For details, see TESTING AND ADJUSTING,
Releasing residual pressure from hydraulic
tank.

k Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.

Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.

2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
a The adapter can be pushed in about 3.5
mm.
a Do not hold rubber cap portion (4).

3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)

4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
a Since some hydraulic oil flows out, prepare
an oil receiving container.

Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
a Do not hold rubber cap portion (4).

2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
a When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.

00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.

2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly

3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.

• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection

00-9
FOREWORD COATING MATERIALS

COATING MATERIALS

a The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
a For coating materials not listed below, use the equivalent of products shown in this list.

Category Komatsu code Part No. Q'ty Container Main applications, featuresr

• Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.

• Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050 (2 pcs.) container ylene, polyprophylene, tetrafluor-
oethlene and vinyl chloride),
rubber, metal and non-metal.

• Features: Resistance to heat and

Polyethylene chemicals
LT-2 09940-00030 50 g container • Used for anti-loosening and seal-
ant purpose for bolts and plugs.

790-129-9060 Adhesive: • Used as adhesive or sealant for

(Set of 1 kg metal, glass and plastic.
LT-3 adhesive and Hardening Can
hardening agent:
agent) 500 g
Adhesives
Polyethylene • Used as sealant for machined
LT-4 790-129-9040 250 g container holes.

Holtz • Used as heat-resisting sealant for

790-126-9120 75 g Tube repairing engine.
MH 705

• Quick hardening type adhesive

Three bond 790-129-9140 50 g Polyethylene • Cure time: within 5 sec. to 3 min.
1735 container • Used mainly for adhesion of met-
als, rubbers, plastics and woods.

• Quick hardening type adhesive

• Quick cure type (max. strength af-
Aron-alpha 790-129-9130 2g Polyethylene ter 30 minutes)
201 container • Used mainly for adhesion of rub-
bers, plastics and metals.

• Resistance to heat, chemicals

Loctite 79A-129-9110 50 cc Polyethylene • Used at joint portions subject to
648-50 container high temperatures.

• Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.

• Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can • Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.

• Features: Silicon based, resist-

ance to heat, cold
LG-6 790-129-9020 200 g Tube • Used as sealant for flange sur-
face, tread.
• mab Used as sealant for oil pan,
final drive case, etc.

00-10
FOREWORD COATING MATERIALS

Category Komatsu code Part No. Q'ty Container Main applications, featuresr

• Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube • Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.

Three bond • Used as heat-resisting sealant for

1211 790-129-9090 100 g Tube repairing engine.

• Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can tion (to prevent from squeaking).
Molybdenum
disulphide • Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
• Used as lubricant for linkage,
bearings, etc.

SYG2-400LI • General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI

SYG2-400CA • Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA

Molybdenum 400 g • Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)

00-11
FOREWORD STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
a In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.

Thread diameter Width across

of bolt flats

mm mm Nm kgm

6 10 13.2 ± 1.4 1.35 ± 0.15

8 13 31 ± 3 3.2 ± 0.3
10 17 66 ± 7 6.7 ± 0.7
12 19 113 ± 10 11.5 ± 1
14 22 177 ± 19 18 ± 2

16 24 279 ± 30 28.5 ± 3
18 27 382 ± 39 39 ± 4
20 30 549 ± 59 56 ± 6
22 32 745 ± 83 76 ± 8.5
24 36 927 ± 103 94.5 ± 10.5

27 41 1320 ± 140 135 ± 15

30 46 1720 ± 190 175 ± 20
33 50 2210 ± 240 225 ± 25
36 55 2750 ± 290 280 ± 30
39 60 3290 ± 340 335 ± 35

Thread diameter Width across

of bolt flats

mm mm Nm kgm

6 10 7.85 ± 1.95 0.8 ± 0.2

8 13 18.6 ± 4.9 1.9 ± 0.5
10 14 40.2 ± 5.9 4.1 ± 0.6
12 27 82.35 ± 7.85 8.4 ± 0.8

Sealing surface

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

a In the case of flared nuts for which there is no special instruction,
tighten to the torque given in the table below.
SAD00483

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

14 19 24.5 ± 4.9 2.5 ± 0.5

18 24 49 ± 19.6 5±2
22 27 78.5 ± 19.6 8±2
24 32 137.3 ± 29.4 14 ± 3
30 36 176.5 ± 29.4 18 ± 3
33 41 196.1 ± 49 20 ± 5
36 46 245.2 ± 49 25 ± 5
42 55 294.2 ± 49 30 ± 5

00-12
FOREWORD STANDARD TIGHTENING TORQUE

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

a In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.

Thread diameter Width across flat Tightening torque

mm mm Nm kgm

10 14 65.7 ± 6.8 6.7 ± 0.7

12 17 112 ± 9.8 11.5 ± 1
16 22 279 ± 29 28.5 ± 3

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

a Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Thread diameter Width across flat Tightening torque

Norminal No.
mm mm Nm kgm

02 14 34.3 ± 4.9 3.5 ± 0.5

03, 04 20 Varies depending 93.1 ± 9.8 9.5 ± 1
05, 06 24 on type of 142.1 ± 19.6 14.5 ± 2
10, 12 33 connector. 421.4 ± 58.8 43 ± 6
14 42 877.1 ± 132.3 89.5 ± 13.5

TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

a Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Thread diameter Width across flat Tightening torque

Norminal No.
mm mm Nm kgm

08 08 14 7.35 ± 1.47 0.75 ± 0.15

10 10 17 11.27 ± 1.47 1.15 ± 0.15
12 12 19 17.64 ± 1.96 1.8 ± 0.2
14 14 22 22.54 ± 1.96 2.3 ± 0.2
16 16 24 29.4 ± 4.9 3 ± 0.5
18 18 27 39.2 ± 4.9 4 ± 0.5
20 20 30 49 ± 4.9 5 ± 0.5
24 24 32 68.6 ± 9.8 7±1
30 30 32 107.8 ± 14.7 11 ± 1.5
33 33 n 127.4 ± 19.6 13 ± 2
36 36 36 151.9 ± 24.5 15.5 ± 2.5
42 42 n 210.7 ± 29.4 21.5 ± 3
52 52 n 323.4 ± 44.1 33 ± 4.5

00-13
FOREWORD STANDARD TIGHTENING TORQUE

TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 ± 2 1.02 ± 0.20
8 24 ± 4 2.45 ± 0.41
10 43 ± 6 4.38 ± 0.61
12 77 ± 12 7.85 ± 1.22

2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 8±2 0.81 ± 0.20
8 10 ± 2 1.02 ± 0.20
10 12 ± 2 1.22 ± 0.20
12 24 ± 4 2.45 ± 0.41
14 36 ± 5 3.67 ± 0.51

3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 3±1 0.31 ± 0.10
1/8 8±2 0.81 ± 0.20
1/4 12 ± 2 1.22 ± 0.20
3/8 15 ± 2 1.53 ± 0.41
1/2 24 ± 4 2.45 ± 0.41
3/4 36 ± 5 3.67 ± 0.51
1 60 ± 9 6.12 ± 0.92

TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
a Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
a Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) type Face seal type
Nominal size Width across
of hose flats Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) inch, Thread series (mm) (Reference)

9
02 19 35 - 63 {3.5 - 6.5} 44 {4.5} 14 – - 18UNF 14.3
16
11
22 54 - 93 {5.5 - 9.5} 74 {4.5} – – - 16UN 17.5
03 16
24 59 - 98 {6.0 - 10.0} 78 {8.0} 18 – –
13
04 27 84 - 132 {8.5 - 13.5} 103 {10.5} 22 – - 16UN 20.7
16
05 32 128 - 186 {13.0 - 19.0} 157 {16.0} 24 1 - 14UNS 25.4
3
06 36 177 - 245 {18.0 - 25.0} 216 {22.0} 30 1 – - 12UNF 30.3
16
(10) 41 177 - 245 {18.0 - 25.0} 216 {22.0} 33 – –
(12) 46 197 - 294 {20.0 - 30.0} 245 {25.0} 36 – –
(14) 55 246 - 343 {25.0 - 35.0} 294 {30.0} 42 – –

00-14
FOREWORD ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.

CLASSIFICATION BY THICKNESS

Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)

0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.

2 26 0.32 2.09 3.1 20 Lighting, signal etc.

5 65 0.32 5.23 4.6 37 Charging and signal

15 84 0.45 13.36 7.0 59 Starting (Glow plug)

40 85 0.80 42.73 11.4 135 Starting

60 127 0.80 63.84 13.6 178 Starting

100 217 0.80 109.1 17.6 230 Starting

CLASSIFICATION BY COLOR AND CODE

Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication

Code W B B R Y G L
1 Pri-
mary
Color White Black Black Red Yellow Green Blue

Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & Red Green & White Blue & White

Code WB — BY RB YB GR LR
3
Color White & Black — Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow

Code WL — BR RY YG GY LY
Auxi-
4 liary
Color White & Blue — Black & Red Red & Yellow Yellow & Green & Blue & Yellow
Green Yellow

Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black

Code — — — RL YW GL —
6
Color — — — Red & Blue Yellow & White Green & Blue —

00-15
FOREWORD CONVERSION TABLE

CONVERSION TABLE

METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.

EXAMPLE
• Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as (A), then draw a horizontal line
from (A).
(2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
(3) Take the point where the two lines cross as (C). This point (C) gives the value when converting from
millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

(B)

Millimeters to inches

1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
(A) 50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

00-16
FOREWORD CONVERSION TABLE

Millimeters to Inches
1 mm = 0.03937 in

0 1 2 3 4 5 6 7 8 9

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929

50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

Kilogram to Pound
1 kg = 2.2046 lb

0 1 2 3 4 5 6 7 8 9

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03

50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

00-17
FOREWORD CONVERSION TABLE

Liter to U.S. Gallon

1l = 0.2642 U.S. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944

50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

Liter to U.K. Gallon

1l = 0.21997 U.K. Gal

0 1 2 3 4 5 6 7 8 9

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778

50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

00-18
FOREWORD CONVERSION TABLE

kgm to ft. lb
1 kgm = 7.233 ft. lb

0 1 2 3 4 5 6 7 8 9

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4

50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1

100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7

150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

00-19
FOREWORD CONVERSION TABLE

kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9

0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9

50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408

100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119

150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830

200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

00-20
FOREWORD CONVERSION TABLE

Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8°F

°C °F °C °F °C °F °C °F

–40.4 –40 –40.0 –11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

–37.2 –35 –31.0 –11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
–34.4 –30 –22.0 –10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
–31.7 –25 –13.0 –10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
–28.9 –20 –4.0 –9.4 15 59.0 10.0 50 122.0 29.4 85 185.0

–28.3 –19 –2.2 –8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

–27.8 –18 –0.4 –8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
–27.2 –17 1.4 –7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
–26.7 –16 3.2 –7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
–26.1 –15 5.0 –6.7 20 68.0 12.8 55 131.0 32.2 90 194.0

–25.6 –14 6.8 –6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

–25.0 –13 8.6 –5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
–24.4 –12 10.4 –5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
–23.9 –11 12.2 –4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
–23.3 –10 14.0 –3.9 25 77.0 15.6 0 140.0 35.0 95 203.0

–22.8 –9 15.8 –3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

–22.2 –8 17.6 –2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
–21.7 –7 19.4 –2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
–21.1 –6 21.2 –1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
–20.6 –5 23.0 –1.1 30 86.0 18.3 65 149.0 37.8 100 212.0

–20.0 –4 24.8 –0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

–19.4 –3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
–18.9 –2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
–18.3 –1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
–17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0

–17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

–16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
–16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
–15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
–15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0

–14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

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

00-21
FOREWORD UNITS

UNITS

In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.

Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}

00-22
GENERAL

01 GENERAL

General assembly drawings ......................................................................................................................... 01-2

Specifications ............................................................................................................................................... 01-3
Weight table .................................................................................................................................................. 01-7
List of lubricant and coolant .......................................................................................................................... 01-9

WA320-5 01-1
GENERAL GENERAL ASSEMBLY DRAWINGS

GENERAL ASSEMBLY DRAWINGS

Symbol Item Unit WA320-5

Operating weight kg 13,450
Rated load kg 4,480
Bucket capacity (piled) m3 2.8
Engine model — KOMATSU SAA6D102E-2-A Diesel engine
Flywheel horse power kW {HP} / rpm 124{166} / 2,000
A Overall length mm 7,455
B Overall height mm 3,200
C Overall height when bucket is raised mm 5,330
D Overall width mm 2,585
E Min. ground clearance mm 425
F Bucket width mm 2,740
G Dumping clearance (Tip of cutting edge/Tip of BOC) mm 2,935 / 2,850
H Dumping reach (Tip of cutting edge/Tip of BOC) mm 995 / 1,035
I Bucket dump angle deg. 45
Tip of cutting edge/Tip of BOC mm 6,025 / 6,090
Min. turning radius
Center of outside wheel mm 5,160
F1 km / h 4.0 – 13.0
F2 km / h 13.0
F3 km / h 18.0
F4 km / h 38.0
Travel speed
R1 km / h 4.0 – 13.0
R2 km / h 13.0
R3 km / h 18.0
R4 km / h 38.0

01-2 WA320-5
GENERAL SPECIFICATIONS

SPECIFICATIONS
Machine model WA320-5

Serial No. 60001 and up

Operating weight kg 13,450

Weight

Distribution (front) SAE travel posture kg 5,980

Distribution (rear) SAE travel posture kg 7,470
Bucket capacity (piled) m³ 2.8
Rated load kg 4,480
Travel speed FORWARD 1st km / h 4.0 – 13.0
FORWARD 2nd km / h 13.0
FORWARD 3rd km / h 18.0
FORWARD 4th km / h 38.0
REVERSE 1st km / h 4.0 – 13.0
Performance

REVERSE 2nd km / h 13.0

REVERSE 3rd km / h 18.0
REVERSE 4th km / h 38.0
Max. rimpull FORWARD kN {kg} 120 {12,200}
REVERSE kN {kg} 120 {12,200}
Gradeability deg. 25
(Center of outside
Min. turning radius wheel) mm 5,160

Min. turning radius [SAE travel posture]

(Tip of cutting edge/Tip of BOC) mm 6,025 / 6,090

Overall length (with BOC) mm 7,455

Overall width (chassis) mm 2,585
Bucket width (with BOC) mm 2,740
Overall height (top of cab) mm 3,200
Overall height (Bucket approx. raised to
max.) mm 5,330

Wheel base mm 3,030

Tread mm 2,050
Dimensions

Min. ground clearance mm 425

Max. height of bucket hinge pin mm 3,905
Dumping clearance (Tip of cutting edge/Tip of BOC) mm 2,935 / 2,850
Dumping reach (Tip of cutting edge/Tip of BOC) mm 995 / 1,035
Steering angle deg. 40
Bucket tilt angle (travel posture) deg. 49
Bucket tilt angle (max. height) deg. 62
Bucket dump angle (max. height) deg. 45
Digging depth (10° dump)
(Tip of cutting edge/Tip of BOC) mm 250 / 295

WA320-5 01-3
GENERAL SPECIFICATIONS

Machine model WA320-5

Serial No. 60001 and up

Model SAA6D102E-2-A
4-cycle, water-cooled, in-line, 6-cylinder,
Type direct injection with turbocharger, aftercooler
No. of cylinders - bore x stroke mm 6 – 102 x 120
Piston displacement l {cc} 5.88 {5,880}
Flywheel horsepower kW / rpm 124 / 2,000
{HP / rpm} {166 / 2,000}
Engine

Maximum torque Nm / rpm 647 / 1,400

{kgm / rpm} {66 / 1,400}
Min. fuel consumption ratio g / kWh {g / HPh} 224 {167}
High idling speed rpm 2,225
Low idling speed rpm 900
Starting motor 24 V 5.5 kW
Alternator 24 V 35 A
Battery 24 V 110 Ah x 2 pcs.
HST pump Variable displacement swash plate-type piston pump
HST motor 1 Variable displacement swash plate-type piston motor
HST motor 2 Variable displacement swash plate-type piston motor
Power train

Multiple shaft planetary compound-type, spur gear

Transfer constant mesh-type, 2 alternative power systems
Reduction gear Spiral bevel gear, splash lubrication type
Differential Straight bevel gear type, torque portioning
Final drive Planetary gear 1-stage, splash lubrication type
Drive type Front and rear wheel drive
Axle

Front axle Fixed to frame, semi-floating type

Rear axle Center pin support, semi-floating type
Tire size 20.5–25–12PR
Rim size 25x17.00–1.7
Tire

Inflation pressure Front tire kPa {kg / cm²} 325 {3.3}

Rear tire kPa {kg / cm²} 275 {2.8}
4 wheel braking, Front and rear wheel independent sys-
Braking system tem control

Main brake Brake type Enclosed wet multiple disc type

Operation method Hydraulically controlled
Brakes

Control method Hydraulic power servo assisted brake

Braking system Transmission gear output shaft braking
Brake type Wet multiple disc type
Parking brake
Operation method Mechanical type
Control method Hand lever type

01-4 WA320-5
GENERAL SPECIFICATIONS

Machine model WA320-5

Serial No. 60001 and up

Type Articulated steering

Steering
control

Control Hydraulic control

Steering pump
• Type Gear type

• Delivery l / min 167

Work equipment pump
• Type Gear type
Hydraulic pump

• Delivery l / min 58
Brake and cooling fan pump
• Type Gear type

• Delivery l / min 31
Transfer lubrication pump
• Type Gear type

• Delivery l / min 22
Hydraulic system

Type Reciprocating piston type

Steering cylinder

Cylinder inner diameter mm 70

Piston rod diameter mm 40
Stroke mm 453
Max. length between pins mm 1,271
Min. length between pins mm 818
Type Reciprocating piston type
Cylinder inner diameter mm 140
Lift cylinder
Cylinder

Piston rod diameter mm 75

Stroke mm 740
Max. length between pins mm 1,969
Min. length between pins mm 1,229
Type Reciprocating piston type
Bucket cylinder

Cylinder inner diameter mm 160

Piston rod diameter mm 80
Stroke mm 532
Max. length between pins mm 1,559
Min. length between pins mm 1,027

WA320-5 01-5
GENERAL SPECIFICATIONS

Machine model WA320-5

Serial No. 60001 and up

Work equipment control valve

• Type 2-spool type
Control valve
Hydraulic system

• Set pressure MPa {kg / cm²} 20.6 {210}

Steering valve
• Type Orbit-roll type

• Set pressure MPa {kg / cm²} 20.6 {210}

Cooling fan motor
Motor

• Type Fixed displacement piston type

equipment

Link type Single link

Work

Bucket edge type Flat blade with top BOC

01-6 WA320-5
GENERAL WEIGHT TABLE

WEIGHT TABLE
a This weight table is a guide for use when transporting or handling components.
Unit: kg

Machine model WA320-5

Serial Numbers 60001 and up

Engine (without coolant and oil) 550
Cooling assembly (without coolant) 70
Cooling fan motor 6
Damper 3
HST pump 80
HST motor 1 60
HST motor 2 60
Transfer 247
Front drive shaft 18
Rear drive shaft 7
Front axle 714
Rear axle 666
Axle pivot (rear axle) 97
Wheel (each) 120
Tire (each) 147
Orbit-roll valve 8
Priority valve 6
Steering cylinder assembly (each) 18
Brake valve 10
Hydraulic tank (without hydraulic oil) 70
4-gear pump unit 30
Work equipment PPC valve 3
Work equipment control valve 65
Lift cylinder assembly (each) 109
Bucket cylinder assembly 124
Engine hood (with side panel) 196
Front frame 1,100
Rear frame 967

WA320-5 01-7
GENERAL WEIGHT TABLE

Unit: kg

Machine model WA320-5

Serial Numbers 60001 and up

Lift arm (including bushing) 915
2
Bucket (2.8m , including BOC) 1,234
Bell crank 253
Bucket link 43
Counterweight 1,950
Additional counterweight (1 piece) (If equipped) 260
Fuel tank (without fuel) 94
Battery (each) 36
Operator’s Cab (including air conditioner and interior parts) 755
(air conditioner: If equipped)
Operator’s seat 41

01-8 WA320-5
GENERAL LIST OF LUBRICANT AND COOLANT

LIST OF LUBRICANT AND COOLANT

AMBIENT TEMPERATURE
KIND OF CAPACITY
RESERVOIR FLUID
Specified Refill

SAE0W-30

SAE5W-40

SAE10W
Engine oil pan 20 19.5
SAE10W-30
Engine oil
SAE 15W-40

SAE30

Transfer case SAE 10W 8.0 6.5

Hydraulic system SAE 10W-30 (*6) 175 89

Axle
(with standard differential) AXO80 (*3) 24 24
Axle oil
Axle (*4)
(with limited-slip differential) (*5) 24 24

ASTM D975 No.2

Diesel fuel
Fuel tank 228
(*2) (*1)

Greasing system Grease NLGI No.2

Cooling system Water Add antifreeze 20

WA320-5 01-9
GENERAL LIST OF LUBRICANT AND COOLANT

*1: ASTM D975 No.1

*2: Use only diesel fuel.
*3: For the standard differential, except for "AX080", the oil for machines equipped with the limited-slip differ-
ential in the table below and E030 can be used. However, in the case of "E030", depending on conditions
such as the way the brakes are used and the oil temperature, the brakes may squeal just before the machine
stops, but there is no problem with the brake performance or durability.
*4: The letters "ASD" are stamped on the name plate of machines equipped with the limited-slip differential axle.
*5: For machines equipped with the limited-slip differential axle, select from the oil given in the table below.
Never use any oil except the oil listed in the table below.

Maker Brand Remarks

SHELL DONAX TD 5W-30 North American manufactured DONAX

TD 20W-40 must not be used
ESSO TORQUE FLUID 56 North American manufactured must
not be used
MOBIL MOBILFLUID 424
FUCHS RENOGEAR HYDRA ZF 20W-40

*6: Please use SAE10W30 for the oil in the hydraulic system. If Komatsu genuine oil is not available, select
the oil from the table below.

Supplier Engine Oil

(The 15W40 oil marked * is CE.)
BP Vanellus C3 (15W40)
Essolube D3
*Essolube XD-3
EXXON *Essolube XD-3 Extra
(ESSO) *Esso heavy duty
Exxon heavy duty
Super duty motor oil
GULF *Super duty plus

MOBIL Delvac 1300

*Delvac super (10W-30, 15W-40)

SHELL Rimura X
Rotella T 10W30

01-10 WA320-5
GENERAL LIST OF LUBRICANT AND COOLANT

REMARK
• When fuel sulphur content is less than 0.5%, change oil in the oil pan according to the periodic maintenance
hours described in this manual.
Change oil according to the following table if fuel sulphur content is above 0.5%.

• When starting the engine with an atmospheric temperature of lower than 0°C (32°F), be sure to use engine
oil of SAE10W, SAE10W-30 and SAE15W-40, even though the atmospheric temperature goes up to 10°C
(50°F) more or less during the day.

• Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval
to half.

• There is no problem if single grade oil is mixed with multigrade oil (SAE10W-30, 15W-40), but be sure to
add single grade oil that matches the temperature range in the table.

• We recommend Komatsu genuine oil which has been specifically formulated and approved for use in engine
and hydraulic work equipment applications.

Specified capacity: Total amount of oil including oil for components and oil in piping.

Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.

ASTM: American Society of Testing and Material

SAE: Society of Automotive Engineers
API: American Petroleum Institute

Fuel suiphur content Charge interval of oil in

engine oil pan
0.5 to 1.0% 1/2 of regular interval
Above 1.0% 1/4 of regular interval

WA320-5 01-11
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD

10 STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD
Engine mount and transfer mount ....................10-2 Accumulator (for PPC circuit)....................... 10-104
Damper.............................................................10-3 Lock valve .................................................... 10-105
Cooling system ................................................. 10-4 E.C.S.S. valve.............................................. 10-106
Power train .......................................................10-5 Accumulator (for E.C.S.S.)........................... 10-108
Power train system diagram .............................10-6 Hydraulic piping of cooling system............... 10-109
Drive shaft (propeller shaft) .............................. 10-8 Cooling fan motor......................................... 10-110
HST hydraulic piping diagram ..........................10-9 Work equipment control valve...................... 10-113
HST pump ......................................................10-10 Work equipment PPC valve ......................... 10-134
High-pressure relief valve...............................10-12 Attachment PPC valve ................................. 10-146
Low-pressure relief valve................................10-14 Work equipment linkage .............................. 10-150
HST charge pump ..........................................10-15 Bucket .......................................................... 10-152
Speed-related valve (DA valve)......................10-16 Bucket positioner and boom kick-out ........... 10-154
High-pressure cut-off valve.............................10-17 Work equipment cylinder ............................. 10-160
HST motor ......................................................10-18 Air conditioner .............................................. 10-161
EP servo valve................................................10-21 Machine monitoring system ......................... 10-162
HA servo valve ...............................................10-22 Machine monitor .......................................... 10-172
Forward-reverse shuttle valve ........................10-23 List of items displayed on monitor................ 10-173
Transfer ..........................................................10-24 Electrical system (HST controller system) ... 10-199
Clutch solenoid valve......................................10-35 HST controller .............................................. 10-203
Axle.................................................................10-36 Engine start circuit ....................................... 10-204
Differential ......................................................10-38 Engine stop circuit........................................ 10-206
Limited-slip differential....................................10-46 Preheating circuit
Final drive .......................................................10-50 (automatic preheating system) .............. 10-207
Axle mounting and center hinge pin ...............10-52 Parking brake circuit .................................... 10-208
Steering piping................................................10-57 Electronically controlled suspension system... 10-211
Steering column..............................................10-58 Sensors........................................................ 10-212
Priority valve ...................................................10-59
Orbit-roll valve ................................................10-62
Cushion valve .................................................10-70
Steering cylinder.............................................10-71
Emergency steering piping .............................10-73
Emergency steering valve ..............................10-74
Brake piping....................................................10-77
Brake valve.....................................................10-78
Inching valve...................................................10-82
Charge valve ..................................................10-84
Accumulator (for brake) ..................................10-88
Slack adjuster .................................................10-90
Brake ..............................................................10-92
Parking brake control......................................10-94
Parking brake .................................................10-95
Hydraulic piping ..............................................10-96
Work equipment lever linkage ........................10-98
Hydraulic tank...............................................10-100
4-gear pump unit ..........................................10-102

WA320-5 10-1
 ENGINE MOUNT AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER MOUNT

ENGINE MOUNT AND TRANSFER MOUNT

10-2 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DAMPER

DAMPER

Unit: mm
No. Check item Criteria Remedy

Distance between HST pump Standard size Repair limit

1 Adjust
mounting face and tip of boss 74.9 ± 0.8
Wear of internal teeth of cou-
2 Repair limit: 1.0 Replace
pling (plastic)

3. Coupling Outline
4. Boss • The damper reduces the torsional vibration
5. HST pump input shaft caused by fluctuation of the engine torque to
6. Cover protect the drive system after the engine from
7. Flywheel the torsional vibration.
• The power from the engine is transmitted
through flywheel (7) to coupling (3), which ab-
sorbs the torsional vibration, and then transmit-
ted through boss (4) to the HST pump.

WA320-5 10-3
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING SYSTEM

COOLING SYSTEM

1. Hydraulic oil cooler 5. Reservoir tank

2. Charge air cooler 6. Cooling fan
3. Radiator 7. Cooling fan motor
4. Transfer oil cooler

Specification

Hydraulic oil Charge air Transfer oil

Radiator
cooler cooler cooler

Core type AL WAVE–4 CF40–1 CF40-1

Fin pitch (mm) 3.5 / 2 3.5 / 2 4.0 / 2 4.5 / 2

Total heat radiating area (m2) 29.86 4.15 7.23 1.87

Pressure valve opening pressure 70 ± 15

— —
(kPa {kg/cm2}) {0.7 ± 0.15}

Vacuum valve opening pressure 0–5

— —
(kPa {kg/cm2}) {0 – 0.05}

10-4 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN

POWER TRAIN

1. Engine
2. Damper
3. HST pump
4. 4-gear pump unit
5. High-pressure hose
6. HST motor 1
7. HST motor 2
8. Transfer
9. Front drive shaft
10. Front axle
11. Rear drive shaft
12. Rear axle

WA320-5 10-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM

POWER TRAIN SYSTEM DIAGRAM

10-6 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD POWER TRAIN SYSTEM DIAGRAM

1. Engine • Parking brake (14) is installed on the rear side in

2. Damper transfer (12). It operates the wet multiple disc
3. HST pump brake to stop the machine according to the oper-
4. Steering pump ation of the parking brake lever.
5. Work equipment pump • The power for the front side is transmitted
6. Brake and cooling fan pump through front drive shaft (15) to front axle (16).
7. Transfer lubricating oil pump The power for the rear side is transmitted
8. High-pressure hose through rear drive shaft (21) to rear axle (22).
9. HST motor 1 • The power transmitted to axles (16) and (22) is
10. HST motor 2 reduced in speed by the pinion gears of differen-
11. Emergency steering valve (If equipped) tials (17) and (23), and then transmitted through
12. Transfer the sun gear shaft to the sun gear.
13. Transfer clutch • The power of the sun gear is reduced in speed
14. Parking brake by the planetary mechanisms of final drives (19)
15. Front drive shaft and (25), and then transmitted through the axle
16. Front axle shaft and wheels to tires (20) and (26).
17. Differential
18. Wet multiple disc brake
19. Final drive
20. Front tire
21. Rear drive shaft
22. Rear axle
23. Differential
24. Wet multiple disc brake
25. Final drive
26. Rear tire

Outline
• The power of engine (1) is transmitted to HST
pump (3) through damper (2) which is installed
to the flywheel and which absorbs the torsional
vibration of the power,
• The power of engine (1) is also transmitted to
HST pump (3), HST charge pump built in HST
pump (3), steering pump (4) connected to HST
pump (3), work equipment pump (5), brake and
cooling fan pump (6), and transfer lubricating oil
pump (7).
• HST pump (3) is equipped with the forward-re-
verse shifting valve and servo piston, which
changes the discharge direction and discharge
rate of HST pump (3) continuously by changing
the swash plate angle.
• HST motors (9) and (10) are installed to transfer
(12) and connected to HST pump (3) by high-
pressure hose (8).
• The turning direction and speed of HST motors
(9) and (10) are changed by the hydraulic power
of HST pump (3) to control the travel direction
and travel speed of the machine.
• The power of HST motor 1 (9) is transmitted
through transfer clutch (13) in transfer (12) to the
output shaft.
The power of HST motor 2 (10) is transmitted
through the gear in transfer (12) to the output
shaft.

WA320-5 10-7
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DRIVE SHAFT (PROPELLER SHAFT)

DRIVE SHAFT (PROPELLER SHAFT)

1. Front axle Outline

2. Front drive shaft • The power from the output shaft of the transfer
3. Transfer is transmitted through front drive shaft (2) and
4. Rear drive shaft rear drive shaft (4) to front axle (1) and rear axle
5. Rear axle (5).
• When the machine is articulated or it receives an
impact from the road during travel or a working
impact, the positions of the transfer and front
and rear axles change. The drive shafts can
change their angles and lengths by means of the
universal joints and sliding joints so that the
power will be transmitted without damaging any
part even when the positions of the components
change because of the impacts.

10-8 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST HYDRAULIC PIPING DIAGRAM

HST HYDRAULIC PIPING DIAGRAM

1. Hydraulic tank
2. HST pump
3. Clutch solenoid valve
4. HST oil filter
5. HST motor 1
6. HST motor 2

WA320-5 10-9
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST PUMP

HST PUMP
a HST: Abbreviation for Hydro Static Transmission

1. Forward-reverse shifting solenoid valve Specifications

2. High-pressure cut-off valve
Model A4VG125DA
3. Speed-related valve (DA valve)
4. Charge pump Variable displacement swash
Type
plate-type piston pump
5. Low-pressure relief valve
6. Servo cylinder Theoretical capacity
0 – 110
7. High-pressure relief valve (cc / rev)
8. Control plate Set pressure of high-pressure
44.1 {450}
9. Cylinder block relief valve (MPa {kg/cm2})
10. Piston Set pressure of high-pressure Effective differential pressure
11. Swash plate cut-off valve (MPa {kg/cm2}) 41.2 {420}

Set pressure of low-pressure

2.94 {30}
relief valve (MPa {kg/cm2})

10-10 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST PUMP

Operation

Flow of power Flow of oil

• The HST pump is installed to the coupling which • As swash plate (11) of the HST pump slants, pis-
is installed to the engine flywheel. tons (10) in contact with its surface reciprocate
• The power of the engine is transmitted from the and work as pumps to suck and discharge the oil
flywheel through the coupling to the HST pump. in cylinder block (9).
• The HST pump is equipped with forward-reverse • As a result, high-pressure oil flows in a constant
shifting solenoid valve (1) and servo cylinder (6). direction into the HST motor.
If the operator operates for forward or reverse • If swash plate (11) slants in the opposite direc-
travel, forward-reverse shifting solenoid valve tion, the sucking and discharging directions of
(1) operates and swash plate (11) in the HST the oil are reversed, that is, the oil flows in the
pump slants to reverse the oil flow. opposite direction. While swash plate (11) is in
• Cylinder block (9) and pistons (10) in it rotate to- neutral, pistons (10) do not reciprocate, thus
gether with drive shaft (12) and the tips of pis- they do not discharge any oil.
tons (10) slide on swash plate (11) which does • The strokes of pistons (10) are changed to con-
not rotate. The pump has 9 pistons (10) in it. trol the travel speed by increasing or decreasing
inclination (angle) of swash plate (11).
• If the quantity of the oil in the low-pressure circuit
(the return circuit from the motor to the pump)
becomes insufficient because of leakage from
the HST pump, HST motor, and control valve,
the charge pump adds oil through speed-related
valve (3) and check valve of high-pressure relief
valve (7).

WA320-5 10-11
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HIGH-PRESSURE RELIEF VALVE

HIGH-PRESSURE RELIEF VALVE

1. Nut Function
2. Locknut • The high-pressure relief valve is installed to the
3. Poppet spring HST pump. If the oil pressure in the high-pres-
4. Check spring sure circuit between the HST pump and HST
5. Main piston motor rises higher than the set pressure, the
6. Valve seat high-pressure relief valve drains the oil into the
7. Pilot poppet low-pressure circuit.
8. Adjustment screw The high-pressure relief valve controls the max-
imum pressure in the circuit to protect the circuit
with this function.
• If the quantity of the oil in the circuit becomes in-
sufficient, the high-pressure valve leads oil in
from the HST charge pump to prevent cavitation.

10-12 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HIGH-PRESSURE RELIEF VALVE

Operation
• Port A is connected to the high-pressure circuit • If the oil pressure in port A and chamber B
of the HST pump and ports C and D are con- reaches the set pressure of poppet spring (3), pi-
nected to the low-pressure circuit of the HST lot poppet (7) opens and the oil in chamber B
pump. flows through chamber D to port C, and the oil
The oil fills chamber B through the orifice of pressure in chamber B lowers consequently.
main piston (5). If the oil pressure in chamber B lowers, a pres-
Pilot poppet (7) is seated on valve seat (6). sure difference is made between port A and
chamber B by the orifice of main piston (5). As
a result, main piston (5) is pushed open and the
oil in port A flows into port C to relieve the abnor-
mal pressure.

• The set pressure can be adjusted by increasing

or decreasing the tension of poppet spring (3).
To adjust the set pressure, remove the nut and
loosen the locknut. If the adjustment screw is
tightened, the set pressure is heightened. If the
former is loosened, the latter is lowered.
• If the oil pressure in port A lowers below that in
port C, check spring (4) pushes back main pis-
ton (5) and the oil in port C flows through cham-
ber D into port A so that the quantity of the oil in
port A will not become insufficient.

WA320-5 10-13
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LOW-PRESSURE RELIEF VALVE

LOW-PRESSURE RELIEF VALVE

1. Locknut
2. Adjustment screw
3. Piston
4. Spring

Function
• The low-pressure relief valve is installed to the
HST pump. If the oil pressure in the low-pres-
sure circuit between the HST pump and HST
motor rises higher than the set pressure, the
low-pressure relief valve drains the oil into the
hydraulic tank.
The low-pressure relief valve controls the pres-
sure in the HST pump charge circuit to protect
the circuit with this function.

Operation
• Port A is connected to the HST pump charge cir-
cuit and port B is connected to the drain circuit.
If the oil pressure is below the set pressure, the
oil does not flow into port B.
• If the pressure in port A reaches the set pres-
sure for some reason, piston (3) opens and the
oil in port A flows into port B, and the oil pressure
in port A lowers consequently.
• The set pressure can be adjusted by increasing
or decreasing the tension of spring (4).
To adjust the set pressure, loosen locknut (1)
and turn adjustment screw (2). If the adjustment
screw is tightened, the set pressure is height-
ened. If the former is loosened, the latter is low-
ered.

10-14 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST CHARGE PUMP

HST CHARGE PUMP

1. Cover bolt Specifications

2. Pump gear
3. Key Gear pump
Type
4. Coupling (Inscribed type)
5. Drive shaft
6. Plate Theoretical capacity
28.3
7. Charge pump cover (cc/rev)
8. Crescent divider board
Function
Outline • The HST charge pump is connected to drive
• The HST charge pump is built in the HST pump shaft (5) of the HST pump and rotated by cou-
and driven together with the HST pump to sup- pling (4).
ply oil to the HST speed-related valve and low- • The HST charge pump has pump gear (2) and
pressure relief valve of the HST pump. crescent divider board (8) in it and sucks and
• The HST charge pump sucks in oil from the hy- discharges the oil in the direction shown in the
draulic tank. above figure.

WA320-5 10-15
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SPEED-RELATED VALVE (DA VALVE)

SPEED-RELATED VALVE (DA VALVE)

1. Locknut
2. Adjustment screw
3. Poppet spring
4. Spring seat
5. Pilot poppet

Function
• The speed-related valve is installed to the HST
pump and used to divide the oil from the HST
charge pump into two parts. One part flows
through a throttle valve to the forward-reverse
shifting solenoid valve of the HST pump and the
other part flows to the low-pressure relief valve
of the HST pump.

Operation
• Port A is connected to the HST pump charge cir-
cuit. Port D is connected to the low-pressure re-
lief valve circuit. Port C is connected to the
forward-reverse shifting solenoid valve circuit.
• The oil from the HST charge pump always flow
through the throttle valve of pilot poppet (5),
chamber B, and port D to the low-pressure relief
valve.
As the hydraulic pressure from the HST charge
pump is applied a differential pressure is gener-
ated between port A and chamber B because of
the throttle valve of pilot poppet (5). Since this
differential pressure moves pilot poppet (5), the
oil flows from chamber B through port C to the
forward-reverse shifting solenoid valve.
• Pilot poppet (5), poppet spring (3), and spring
seat (4) are used as a set. To change the set
pressure, loosen locknut (1) and turn the adjust-
ment screw (2). If the adjustment screw is tight-
ened, the set pressure is lowered. If the former
is loosened, the latter is heightened.

10-16 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HIGH-PRESSURE CUT-OFF VALVE

HIGH-PRESSURE CUT-OFF VALVE

1. Adjustment screw
2. Locknut
3. Spring
4. Spool
5. Piston
6. Barrel
7. Shuttle spool
8. Valve seat

Function
• The high-pressure cut-off valve is installed to the
HST pump. If the oil pressure in the high-pres-
sure circuit between the HST pump and HST
motor rises higher than the set pressure, the
high-pressure cut-off valve drains the oil from
the servo cylinder circuit into the hydraulic tank
to control the maximum pressure in the HST
pump circuit.

Operation
• Port A is connected to the high-pressure circuit
during reverse travel. Port B is connected to the
high-pressure circuit during forward travel. Port
Pc is connected to the speed-related valve, and
port T is connected to the drain circuit.
• If the pressure on the port A side rises high for
some reason, shuttle spool (7) is pushed down
and the circuit on port B side is closed. At the
same time, piston (5) is pushed up by the hy-
draulic pressure on port A side and spring (3) is
compressed and spool (4) is also pushed up.
Then, ports Pc and T are opened and the hy-
draulic oil in the speed-related valve circuit flows
into the drain port.
As a result, the oil pressure in port Pc lowers and
the swash plate angle of the HST pump reduces,
and consequently the discharge reduces and
the abnormal pressure in the HST pump circuit
lowers.

WA320-5 10-17
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST MOTOR

HST MOTOR
a HST: Abbreviation for Hydro Static Transmission
HST motor 1

1. Drive shaft Specifications

2. Piston
Model A6VM150EP
3. Cylinder block
4. Port plate Variable displacement swash
Type
plate-type piston motor
5. EP servo valve
Theoretical capacity (cc/rev) 0 – 140
Set pressure of high-pressure
44.1 {450}
relief valve (MPa {kg/cm2})
Set pressure of high-pressure Effective differential pressure
cut-off valve (MPa {kg/cm2}) 41.2 {420}
Set pressure of low-pressure
2.94 {30}
relief valve (MPa {kg/cm2})

10-18 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST MOTOR

HST motor 2

1. Drive shaft Specifications

2. Piston
Model A6VM140HA
3. Cylinder block
4. Port plate Variable displacement swash
Type
plate-type piston motor
5. HA servo valve
6. Forward-reverse shuttle valve Theoretical capacity (cc/rev) 50 – 140
Set pressure of high-pressure
44.1 {450}
relief valve (MPa {kg/cm2})
Set pressure of high-pressure Effective differential pressure
cut-off valve (MPa {kg/cm2}) 41.2 {420}
Set pressure of low-pressure
2.94 {30}
relief valve (MPa {kg/cm2})

WA320-5 10-19
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST MOTOR

Principle Operation
• Let's assume that a shaft of a disc is supported • The hydraulic oil sent from the HST pump flows
and the disc can rotate freely. If force F is ap- in the inlet port of the HST motor and gives hy-
plied bias to this disc, it is divided into compo- draulic pressure to the back side of pistons (2).
nent force F1 at right angles to the disc and Accordingly, drive shaft (1) rotates because of
component force F2 in the peripheral direction of inclination of pistons (2) and cylinder block (3).
the disc. Component force F2 rotates the disc to • The oil from the HST pump flows between the
the right. forward-reverse shifting solenoid valve and ser-
• If force F', not force F, is applied to the disc, it is vo cylinder into forward-reverse shuttle valve (6)
divided into component forces F1' and F2' simi- of the HST motor. The oil from the forward or re-
larly to the above and force F2' rotates the disc verse high-pressure discharge side of the HST
to the left motor flows into forward-reverse shuttle valve
(6). If a load is applied to the motor connected
to servo valve (5) in the HST motor, the oil flows
into the servo cylinder of the HST motor be-
cause of the pressure difference from forward-
reverse shuttle valve (6) side, thus cylinder block
(3) is inclined more.

Structure

• There are 7 pistons (2) installed to the disc por-

tion of the drive shaft (1) as if they are spherical
joints. They are set in cylinder block (3) at a cer-
tain angle to drive shaft (1).
• As the external load on the HST motor is in-
creased by servo valve (5) and forward-reverse
shuttle valve (6), inclination of pistons (2) is in-
creased. As a result, the revolving speed is low-
ered but the torque is increased.

10-20 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EP SERVO VALVE

EP SERVO VALVE

1. Motor 1 solenoid valve Operation

2. EP servo valve • Suction force F1 of motor 1 solenoid valve (1)
3. Spring and force F2 of spring (3) are applied to EP ser-
4. Servo cylinder vo valve (2).
• If the current given to motor 1 solenoid valve (1)
Function is little (F1 < F2), EP servo valve (2) leads the
• The EP servo valve is installed to the rear part of hydraulic pressure of the motor high-pressure
HST motor 1 and used to change the displace- circuit to the small diameter (S) side of servo cyl-
ment of the motor according to the current given inder (4) and releases the hydraulic pressure on
to motor 1 solenoid valve (1). the large diameter (L) side into the tank (motor
housing). As a result, servo cylinder (4) moves
toward the min side.
• If the current given to motor 1 solenoid valve (1)
is large (F1 > F2), EP servo valve (2) leads the
hydraulic pressure to the large diameter (L) side.
As a result, servo cylinder (4) moves toward the
max side because of the area difference be-
tween the small diameter (S) side and large di-
ameter (L) side.
• The force of spring (3) changes according to the
position of servo cylinder (4) (the displacement
of the motor).
Accordingly, the displacement of the motor is
controlled by the current given to motor 1 sole-
noid valve (1) so that suction force F1 will be bal-
anced with spring force F2.

WA320-5 10-21
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HA SERVO VALVE

HA SERVO VALVE

1. Motor 2 solenoid valve Operation

2. HA servo valve • When the load on the machine is small, HA ser-
3. Servo cylinder vo valve (2) leads the hydraulic pressure on the
side selected by the forward-reverse shuttle
Function valve to the small diameter (S) side of servo cyl-
• The HA servo valve is installed to the rear part of inder (3) and releases the hydraulic pressure on
HST motor 2 and used to control the position of the large diameter (L) side into the tank (motor
servo cylinder (3) (the displacement of the mo- housing) to minimize the displacement of the
tor) to meet the motor output to the external load motor.
on the motor. The displacement is controlled • When a large load is applied to the machine on
with the hydraulic pressure in the circuit selected a uphill, etc., HA servo valve (2) leads the hy-
by the forward-reverse shuttle valve. draulic pressure to the large diameter (L) side.
As a result, servo cylinder (3) moves toward the
max side because of the area difference be-
tween the small diameter (S) side and large di-
ameter (L) side. At this time, the displacement
of the motor becomes largest and the motor
generates large torque.
• If motor 2 solenoid valve (1) is energized, HA
servo valve (2) leads the hydraulic pressure to
the large diameter (L) side and the displacement
of the motor becomes largest, regardless of the
load on the machine.

10-22 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FORWARD-REVERSE SHUTTLE VALVE

FORWARD-REVERSE SHUTTLE VALVE

1. Forward-reverse shifting solenoid valve Operation

2. Forward-reverse shuttle valve • The electric signals given to the forward-reverse
shifting solenoid valve of the HST pump are
Function used for forward-reverse shifting solenoid valve
• The forward-reverse shuttle valve is installed to (1) and linked to the forward-reverse shifting
the rear part of HST motor 2 and used to grasp mechanism.
and change the position of the forward-reverse • Forward-reverse shuttle valve (2) changes the
shifting solenoid valve to control where to lead hydraulic pressure applied to the HA servo valve
the hydraulic pressure for the HA servo valve. according to the forward-reverse shifting com-
Accordingly, shocks made when the oil pressure mand.
changes for gear shifting are reduced.

WA320-5 10-23
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER

TRANSFER

a. Clutch port Relationship between transfer clutch and

b. Lubricating oil inlet port transfer clutch pressure at each gear speed
c. Lubricating oil suction port
Gear
Transfer clutch Transfer clutch pressure
speed
1. HST motor 2 mount
2. HST motor 1 mount 1st Engaged OFF
3. Oil filler pipe
2nd Engaged OFF
4. Transfer
5. Parking brake lever Travel speed Travel speed Travel speed Travel speed
6. Speed sensor 3rd 0 – 10km/h 10 – 18km/h 0 – 10km/h 10 – 18km/h

Engaged Disengaged OFF ON

Outline
• The transfer is equipped with 2 HST motors. Travel speed Travel speed Travel speed Travel speed
0 – 10km/h 10 – 38km/h 0 – 10km/h 10 – 38km/h
The engine speed is changed to the forward 1st 4th
– 4th and rear 1st – 4th gear speeds by combin- Engaged Disengaged OFF ON
ing the output and revolving direction of the HST
motor and the transfer clutch. Note: The travel speed when tires of 20.5 – 25 size
are used is shown in the table.

10-24 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER

1. HST motor 1 8. Motor 1 gear (Number of teeth: 50)

2. Input shaft 9. Sun gear (Number of teeth: 37)
3. Transfer clutch 10. Parking brake
4. Carrier 11. Rear coupling
5. Ring gear (Number of teeth: 86) 12. Output gear (Number of teeth: 55)
6. Planetary gear (Number of teeth: 24) 13. Output shaft
7. Planetary shaft 14. Front coupling

WA320-5 10-25
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER

Input shaft portion

Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between input shaft size Shaft Hole clearance limit
1
and bearing (F)
++0.012 +0 -0.024 –
ø60 –
+-0.007 -0.012 0.007
Clearance between input shaft ++0 ++0.016 -0.006 –
2 ø95 –
bearing and cage (F) -0.013 -0.006 0.029
Clearance between input shaft +0.011 +0 -0.023 – Replace
3 ø50 –
and bearing (M) -0.005 -0.012 0.005
Clearance between input shaft +0 ++0.013 -0.006 –
4 ø80 –
bearing and ring gear (M) -0.013 -0.006 0.026
Clearance between input shaft +0.011 +0 -0.023 –
5 ø50 –
and bearing (R) -0.005 -0.012 0.005
Clearance between input shaft +0 +0.013 -0.006 –
6 ø80 –
bearing and carrier (R) -0.013 -0.006 0.026

10-26 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER

No. Check item Criteria Remedy

Clearance between press-fit +0.039 +0 -0.054 –

7 ø55 –
shaft and bearing +0.020 -0.015 -0.020
Clearance between press-fit +0 -0.016 -0.038 –
8 ø100 –
shaft bearing and motor 1 gear -0.018 -0.038 0.002
Clearance between piston and -0.085 +0.040 0.085 –
9 ø177 –
spacer -0.125 +0 0.165
Clearance between piston and -0.550 +0.046 0.550 –
10 ø222 –
cage -0.650 +0 0.696
Clearance between clutch +0.061 +0.046 -0.061 –
11 ø200 –
housing and front case +0.015 +0 0.031
Standard size Tolerance Repair limit
Thickness of separator plate
12 1.7 ±0.05 1.6
Distortion of separator plate – 0.05 0.15
Thickness of friction plate 2.2 ±0.08 1.8
13
Distortion of friction plate – 0.02 0.25
Load on wave spring (Height: 1,147 N ±115 N 918 N
14
2.2 mm) {117 kg} {±11.7 kg} {94 kg}
Inside diameter of contact face +0.021
ø25 ø25.1
of seal ring +0
+0.15
Width of groove of seal ring 2.5 2.7
15 +0.10
Replace
-0.01
Width of seal ring 2.5 2.3
-0.03
Thickness of seal ring 1.2 ±0.1 1.05
Inside diameter of contact face +0.035
ø90 ø90.1
of seal ring +0
+0.15
Width of groove of seal ring 3 3.3
16 +0.10
-0.01
Width of seal ring 3 2.7
-0.03
Thickness of seal ring 3.7 ±0.12 3.55
Inside diameter of contact face +0.022
ø120 ø120.5
of seal ring +0
+0.1
Width of groove of seal ring 4.5 5.0
17 +0
+0
Width of seal ring 4.36 3.9
-0.1
Thickness of seal ring 3 ±0.1 2.7
Backlash between motor 1 gear
18 0.19 – 0.465
and output gear
Side clearance of planetary
— 0.35 – 0.80
gear (on both sides)

WA320-5 10-27
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER

Output shaft portion

10-28 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER

Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between output size Shaft Hole clearance limit
1
shaft and bearing (F)
+0.030 +0 -0.045 –
ø 60 –
+0.011 -0.015 -0.011
Clearance between output +0 -0.015 -0.040 –
2 ø 110 –
shaft bearing and cage (F) -0.018 -0.040 0.003
Clearance between output +0.030 +0 -0.045 –
3 ø 65 –
shaft and bearing (R) +0.011 -0.015 -0.011
Clearance between output +0 -0.015 -0.040 –
4 ø 120 –
shaft bearing and rear case (R) -0.018 -0.040 0.003
Clearance between oil seal and +0.170 +0.054 -0.170 –
5 ø 100 –
cage (F) +0.080 +0 -0.026 Replace
Clearance between dust seal +0.400 +0.054 -0.400 –
6 ø 100 –
and cage (F) +0.200 +0 -0.146
Clearance between oil seal and +0.170 +0.054 -0.170 –
7 ø 100 –
cage (R) +0.080 +0 -0.026
Clearance between dust seal +0.400 +0.054 -0.400 –
8 ø 100 –
and cage (R) +0.200 +0 -0.146
Standard size Tolerance Repair limit
Inside diameter of sliding sur-
9 0
face of coupling oil seal (F) ø 75 74.8
-0.074
Inside diameter of sliding sur- 0
10 ø 75 74.8
face of coupling oil seal (R) -0.074
Standard Clearance
Clearance between cage and Standard size
11 clearance limit
front case
0.7 0.1 – 1.3 – Adjust shim
Free rotation torque of output
12 4.9 – 6.7 Nm {0.5 – 0.7 kgm}
shaft

WA320-5 10-29
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER

10-30 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER

1. HST motor 2
2. Motor 2 gear (Number of teeth: 50)
3. Strainer
4. Drain plug

Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between input shaft size Shaft Hole clearance limit
5
and bearing (F)
+0.035 +0 -0.050 –
ø 65 –
+0.013 -0.015 -0.013
Replace
Clearance between input shaft +0 +0.022 -0.013 –
6 ø 120 –
bearing and cage (F) -0.015 -0.013 0.037
Backlash between motor 2 gear
7 0.190 – 0.465
and output gear

WA320-5 10-31
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER

Operation of clutch

When clutch is ON (fixed) When clutch is OFF (released)

• If the oil from the clutch solenoid valve is shut • The oil sent from the clutch solenoid valve is
off, piston (2) is moved to the right by the tension sent by pressure to the back side of piston (2)
of spring (1). and it pushes back spring (1) and piston (2)
Plates (3) and discs (4) are fixed to each other moves to the left. The friction force of plates (3)
and rotation of discs (4) is stopped by their fric- and discs (4) is lost and ring gear (5) is set in
tion force and ring gear (5) meshed with the in- neutral.
ternal teeth is fixed. • Wave springs (6) installed between plates (3) re-
turn piston (2) quickly and separate plates (3)
and discs (4) to prevent increase of slip loss
when the clutch is disengaged.

10-32 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER

Low-speed mode

Operation
• In the low-speed mode, transfer clutch (1) is
fixed and the power of both HST motor 1 (2) and
HST motor 2 (3) is transmitted to output shaft
(11).
• The power of HST motor 1 (2) is transmitted
through input shaft (4), sun gear (5), planetary
gear (6), carrier (7), motor 1 gear (8), and output
gear (10) to output shaft (11).
• The power of HST motor 2 (3) is transmitted
through motor 2 gear (9) and output gear (10) to
output shaft (11).

WA320-5 10-33
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD TRANSFER

High-speed mode

Operation
• In the high-speed mode, transfer clutch (1) is re-
leased and HST motor 1 (2) stops. Accordingly,
the power of only HST motor 2 (3) is transmitted
to output shaft (11).
• The power of HST motor 2 (3) is transmitted
through motor 2 gear (9) and output gear (10) to
output shaft (11).

10-34 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CLUTCH SOLENOID VALVE

CLUTCH SOLENOID VALVE

P: From HST charge pump Operation

A: To transfer clutch • When the current of the input signal is large, the
T: To drain port hydraulic oil of the transfer clutch is drained.
• As the current of the input signal is reduced, the
1. Clutch solenoid valve hydraulic pressure of the transfer clutch is
2. Plunger heightened.
3. Coil • After the current of the input signal is reduced
4. Push pin until the hydraulic pressure of the transfer clutch
5. Spring reaches the hydraulic pressure sent from the
6. Spool HST charge pump, the hydraulic pressure of the
7. Body transfer clutch is kept at the hydraulic pressure
sent from the HST charge pump even if the cur-
rent of the input signal is reduced further.

WA320-5 10-35
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AXLE

AXLE
FRONT AXLE

1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Shaft
8. Oil filler port / level plug
9. Slack adjuster
10. Oil temperature sensor
11. Drain plug

10-36 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AXLE

REAR AXLE

1. Differential
2. Final drive
3. Axle shaft
4. Axle housing
5. Wet-type multiple-disc brake
6. Coupling
7. Oil filler port / level plug
8. Slack adjuster
9. Drain plug

WA320-5 10-37
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL

DIFFERENTIAL
FRONT DIFFERENTIAL

1. Pinion gear (Number of teeth: 9)

2. Shaft
3. Bevel gear (Number of teeth: 42)
4. Sun gear shaft
5. Bevel pinion (Number of teeth: 10)
6. Side gear (Number of teeth: 12)

10-38 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL

Unit: mm
No. Check item Criteria Remedy

7 Backlash of differential gear 0.1 – 0.25

6.3 – 21.1 Nm {0.64 – 2.15 kgm} Adjust
8 Starting torque of bevel gear
(At outside surface of bevel gear)
Standard size Tolerance Repair limit
9 Pinion gear washer thickness
3 ± 0.08 2.8 Replace
10 Side gear washer thickness 4 ± 0.05 3.8
Thickness of shim at differential
11 0.30 – 1.25
side bearing carrier (Each side) Adjust
12 Backlash of bevel gear 0.20 – 0.33
13 End play of bevel pinion 0 – 0.165 Replace
Thickness of shim at differential
14 1.07 ± 0.33 Adjust
housing and gauge assembly

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
Clearance of differ- Outer +0 -0.041 -0.076 –
15 ø 120 —
ential side bearing race -0.020 -0.076 -0.021
Inner +0.051 +0 -0.066 –
ø 75 —
race +0.032 -0.015 -0.032
Outer +0 -0.048 -0.088 –
Clearance of bear- race ø 140 —
-0.018 -0.088 -0.030
16 ing on gear side of
pinion shaft Inner +0.039 +0 -0.054 –
ø 65 —
race +0.020 -0.015 -0.020
Outer +0 -0.041 -0.076 –
Clearance of bear- race ø 120 —
-0.015 -0.076 -0.026
17 ing on coupling
side of pinion shaft Inner +0.039 +0 -0.054 – Replace
ø 55 —
race +0.020 -0.015 -0.020
Clearance between pinion gear -0.06 +0.10 0.11 –
18 ø 28 —
and spider -0.11 +0.05 0.21
Clearance of piston fitting por-
-0.110 +0.081 0.110 –
19 tion of differential housing ø 268.5 —
-0.191 +0 0.272
(Housing and piston)
Clearance of piston fitting por-
-0.100 +0.072 0.100 –
20 tion of bearing carrier (Piston ø 247 —
-0.172 +0 0.244
and carrier)

Clearance Outer +0 +0 -0.035 –

ø 110 —
between drive race -0.015 -0.035 0.015
21
shaft and bearing Inner +0.018 +0 -0.030 –
of cage ø 50 —
race +0.002 -0.012 -0.002

WA320-5 10-39
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL

REAR DIFFERENTIAL

1. Pinion gear (Number of teeth: 9)

2. Shaft
3. Bevel gear (Number of teeth: 42)
4. Sun gear shaft
5. Bevel pinion (Number of teeth: 10)
6. Side gear (Number of teeth: 12)

10-40 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL

Unit: mm
No. Check item Criteria Remedy

7 Backlash of differential gear 0.1 – 0.25

6.3 – 21.1 Nm {0.64 – 2.15 kgm} Adjust
8 Starting torque of bevel gear
(At outside surface of bevel gear)
Standard size Tolerance Repair limit
9 Pinion gear washer thickness
3 ± 0.08 2.8 Replace
10 Side gear washer thickness 4 ± 0.05 3.8
Thickness of shim at differential
11 0.30 – 1.25
side bearing carrier (Each side) Adjust
12 Backlash of bevel gear 0.20 – 0.33
13 End play of bevel pinion 0 – 0.165 Replace
Thickness of shim at differential
14 1.07 ± 0.33 Adjust
housing and gauge assembly

Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
Clearance of differ- Outer +0 -0.041 -0.076 –
15 ø 120 —
ential side bearing race -0.020 -0.076 -0.021
Inner +0.051 +0 -0.066 –
ø 75 —
race +0.032 -0.015 -0.032
Outer +0 -0.048 -0.088 –
Clearance of bear- race ø 140 —
-0.018 -0.088 -0.030
16 ing on gear side of
pinion shaft Inner +0.039 +0 -0.054 –
ø 65 —
race +0.020 -0.015 -0.020
Outer +0 -0.041 -0.076 – Replace
Clearance of bear- race ø 120 —
-0.015 -0.076 -0.026
17 ing on coupling
side of pinion shaft Inner +0.039 +0 -0.054 –
ø 55 —
race +0.020 -0.015 -0.020
Clearance between pinion gear -0.06 +0.10 0.110 –
18 ø 28 —
and spider -0.11 +0.05 0.210
Clearance of piston fitting por-
-0.110 +0.81 0.110 –
19 tion of differential housing ø 268.5 —
-0.191 +0 0.272
(Housing and piston)
Clearance of piston fitting por-
-0.100 +0.072 0.100 –
20 tion of bearing carrier (Piston ø 247 —
-0.172 +0 0.244
and carrier)

Clearance Outer +0 +0 -0.035 –

ø 110 —
between drive race -0.015 -0.035 0.015
21
shaft and bearing Inner +0.018 +0 -0.030 –
of cage ø 50 —
race +0.002 -0.012 -0.002

WA320-5 10-41
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL

Outline When turning

• The power transmitted to the front and rear axles • When turning, the rotating speed of the left and
is turned by 90 degrees and reduced in speed, right wheels is different, so pinion gear (4) and
and then transmitted through pinion gear (4) to side gear (3) inside the differential transmit the
sun gear shaft (2). power of carrier (6) to sun gear shaft (2) while ro-
• The power of the sun gear is further reduced by tating in accordance with the difference between
the planetary gear type final drive and is trans- the left and right rotating speeds.
mitted to the axle shaft and wheels.

When traveling in a straight line

• When traveling in a straight line, the rotating
speed of the left and right wheels is the same, so
pinion gear (4) inside the differential assembly
does not rotate. The power of carrier (6) passes
through pinion gear (4) and side gear (3), and is
transmitted equally to the left and right sun gear
shafts (2).

10-42 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL

Torque proportioning differential

Outline
• A 4-wheel-drive wheel loader, as a construction
machine, must naturally work on places where
the ground condition is bad. If its tires slip in
such places, its function lowers and the lives of
the tires are shortened. To solve this problem,
the torque proportioning differential is used.
• Differential pinion gear (4) of this differential has
an odd number of teeth. The meshing points of SAW02536
pinion gear (4) and side gears (3) change ac-
cording to the difference of the road resistance.
Consequently, the traction forces of the tires on
both sides change.

SEW00080

WA320-5 10-43
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD DIFFERENTIAL

Operation

Straight travel (When the road resistances under

both tires are the same)
• When the road resistances under the both tires
are the same, distance "a" from differential pin-
ion (4) to the meshing point of left side gear (7)
and distance "b" to the meshing point of right SAW00491
side gear (3) are the same.
• Accordingly, left traction force TL and right trac-
tion force TR are balanced.

Travel on soft ground (When the road

resistances under both tires are different)
• When the tires slips on soft ground, the side
gear of the tire on the less road resistance side
turns forward. As a result, the meshing points of
pinion gear (4) and the side gears change.
• If left side gear (7) turns forward a little, distance
"a" from the pinion gear to the meshing point of
the left side gear becomes longer than distance
"b" to the meshing point of the right side gear, SAW00492
and then "a" and "b" are balanced at a point
where a x TL = b x TR. The ratio of a:b changes
up to 1:1.38, depending on the meshing condi-
tion.
• Accordingly, the pinion gear does not run idle
and the drive force is transmitted to both side
gears and the tires do not slip until the ratio of
a:b becomes 1:1.38, or the difference between
the road resistances under both tires becomes
38%.
• The lives of the tires are lengthened 20 - 30%
and the working capacity is increased by the
above effect.

10-44 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIMITED-SLIP DIFFERENTIAL

LIMITED-SLIP DIFFERENTIAL
FRONT

1. Plate
2. Disc
3. Pinion (Number of teeth:12)
4. Washer
5. Side gear(Number of teeth:24)
6. Bevel pinion
7. Shaft
8. Pressure ring
9. Bevel gear
10. Case

10-46 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIMITED-SLIP DIFFERENTIAL

Unit: mm
No. Check item Criteria Remedy

Standard size Tolerance Repair limit

11 Plate thickness 3
± 0.02 2.9
3.1
+0.04
12 Disc thickness 2.5 2.45
-0.03
2
13 Washer thickness ± 0.03 1.8
2.1
Clearance between disc and
14 0.20 – 0.6
plate (Total of both sides)
Replace
End play (one end ) of side
15 0.15 – 0.35
gear in axial direction
Backlash between case and
16 0.1 – 0.6
plate
Backlash between side gear
17 0.13 – 0.36
and disc

Standard Tolerance Standard Clearance

Clearance between spider and size Shaft Hole clearance limit
18
differential pinion gear
-0.110 +0.05 0.110 –
ø 28 —
-0.160 +0 0.210

WA320-5 10-47
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIMITED-SLIP DIFFERENTIAL

Operation of limited-slip differential When traveling in a straight line

1. When there is no imbalance between drive

The power is transmitted from bevel gear (9) to case
force of left and right wheels [Road surface
(10), pressure ring (8), shaft (7), pinion (3), and gear
condition (friction coefficient) and load for left
(5), and is divided to the left and right shafts.
and right wheels are uniform and load on bucket
The brake system, consisting of discs (2) and plates
is centered exactly]
(1) is installed at the rear face of side gear (5). A
The power is divided equally to the left and right
brake torque is generated that is proportional
by the differential gear. In this case, the wheel
to the torque transmitted from pressure ring (8) to
slip limit of the left and right wheels is the same,
shaft (7).
so even if the power from the engine exceeds
This brake torque acts to limit the rotation in relation
the wheel slip limit, both wheels will slip and the
to side gear (5) and case (10), so it is difficult for left
differential will not be actuated.
and right side gears (5) to rotate mutually and the op-
There is no load on the brake at the rear face of
eration of the differential is limited.
the side gears.
Brake torque generation mechanism of left and
right side gears (5).
Shaft (7) is supported at the cam surface cut into the
facing surfaces of left and right pressure rings (8).
The power (torque) transmitted from pressure rings
(8) to shaft (7) is transmitted at the cam surface, but
force Fa separating left and right pressure rings (8)
is generated in proportion to the torque transmitted
according to the angle of this cam surface.
This separation load Fa acts on the brake at the rear
face of left and right side gears (5) and generates
the brake torque.

10-48 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LIMITED-SLIP DIFFERENTIAL

2. When there is imbalance between drive force Difference in wheel drive force for each type of differ-
of left and right wheels [Road surface condi- ential when wheel on one side slips
tion (friction coefficient) and load for left and Wheel drive force
right wheels are not uniform and it is easier for (when one wheel is slipping)
wheel on one side to slip] Slipping Locked Total
Example 1. When digging, and wheel on one wheel wheel (ratio)
side is on soft surface Limited-slip differential 3.64
Example 2. When clearing snow, and wheel on 1 2.64
(option) (1.82)
one side is on snow and wheel on other side is Torque proportioning
on asphalt 1 1.38 2.38 (1)
differential (standard)
Example 3. When traveling on slope, and there
Normal differential 1 1 2 (0.84)
is imbalance between load on left and right
wheels
The power is divided equally to the left and right On road surfaces where the wheel on one side is
by the differential gear. However, when the likely to slip, the limited-slip differential increases
drive force exceeds the wheel slip limit on the the drive force by 1.53 times more than the torque
side where the wheel is slipping, the amount of proportioning differential.
the force exceeding the wheel slip limit passes
through the brake and case at the rear face of When turning
the side gear and is transmitted to the brake on The differential gears built into a limited-slip differen-
the opposite side (locked side) and is sent to tial are the same as the gears used in a normal dif-
the wheel on the locked side. ferential, so the difference in rotation between the
If this excess portion of the drive force becomes inside and outside wheels when turning the machine
greater than the braking force, the differential can be generated smoothly.
starts to work.

WA320-5 10-49
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE

FINAL DRIVE

1. Planet gear (No. of teeth: 26)

2. Planetary carrier
3. Axle shaft
4. Ring gear (No. of teeth: 69)
5. Sun gear shaft (No. of teeth: 15)
Unit: mm
No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between pinion gear size Clearance limit
6 Shaft Hole
bearing and shaft
Replace
+0.025 +0.013 -0.025 –
ø 33.338 +0.013 +0 0 —

Clearance between axle housing +0.100 +0.100 -0.060 –

7 and ring gear ø 316 +0.030 +0.040 +0.070 —

Clearance between oil seal and

8 housing Max. 0.2 Adjust

+0.400 +0.063 -0.4 –

Housing ø 155 +0.200 +0 -0.137 —
Press-fitting portion
9 of axle shaft seal +0 -0.200 -0.4 –
Shaft ø 115 -0.054 -0.400 -0.146 —

+0.025 -0.012 -0.077–

Clearance at press- Outer race ø 152.4 +0 -0.052 -0.012 —
10 fitting portion of axle Replace
housing bearing +0.073 +0.025 -0.073 –
Inner race ø 92.075 +0.051 +0 -0.026 —

+0 -0.038 -0.078 –
Clearance at press- Outer race ø 130 -0.025 -0.078 -0.013 —
11 fitting portion of axle
housing bearing +0.035 +0 -0.055 –
Inner race ø 85 +0.013 -0.020 -0.013 —

12 End play of axle shaft 0 – 0.1 Adjust

+0.025 +0.207 0.120 –

13 Clearance of guide pin ø 12 +0.007 +0.145 0.200 — Replace

10-50 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD FINAL DRIVE

Outline
• The final drive finally reduces the speed of the
power transmitted from the HST motor through
the transfer to the axle and increases the drive
force.
• Ring gear (4) is press fitted to the axle housing
and is fixed in position by a pin.
• The power transmitted from the differential and
passing through sun gear shaft (5) has its speed
reduced by the planetary gear mechanism and
the drive force increased.
The increased drive force passes through plan-
etary carrier (2) and axle shaft (3) and is trans-
mitted to the wheels.

WA320-5 10-51
 AXLE MOUNTING AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER HINGE PIN

AXLE MOUNTING AND CENTER HINGE PIN

10-52 WA320-5
 AXLE MOUNTING AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER HINGE PIN

1. Front axle Outline

2. Tension bolt • Since front axle (1) receives forces directly dur-
3. Front frame ing work, it is fixed to front frame (3) directly with
4. Center hinge pin tension bolts (2).
5. Rear axle • Rear axle (5) rocks at the center of rear frame (6)
6. Rear frame so that each tire will keep in contact with ground
7. Additional counterweight (If equipped) even when the machine travels on soft ground.
8. Counterweight • Front frame (3) and rear frame (6) are connected
by center hinge pin (4) with the bearing between
them. The steering cylinders on both sides con-
nect front frame (3) and rear frame (6) and move
to adjust the bending angle, or the turning radi-
us.

WA320-5 10-53
 AXLE MOUNTING AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER HINGE PIN

10-54 WA320-5
 AXLE MOUNTING AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER HINGE PIN

Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between upper size Shaft Hole clearance limit
1
hinge pin and rear frame
-0.030 +0.046 0.030 –
ø 75 –
-0.076 +0 0.122
Clearance between upper -0.030 +0.250 0.030 –
2 ø 75 –
hinge pin and spacer (small) -0.076 +0 0.326
Clearance between upper -0.030 +0 0.015 –
3 ø 75 –
hinge pin and bearing -0.076 -0.015 0.076
Clearance between upper -0.030 +0.026 0.010 –
4 ø 75 –
hinge pin and spacer (large) -0.076 -0.020 0.102
Clearance between rear frame -0.010 +0.054 0.010 –
5 ø 90 –
and spacer (large) -0.040 +0 0.094
Clearance between front frame +0 -0.030 -0.076 –
6 ø 120 – Replace
and upper hinge bearing -0.020 -0.076 -0.010
Clearance between lower hinge -0.030 +0.067 0.057 –
7 ø 75 –
pin and rear frame bushing -0.076 +0.027 0.143
Clearance between lower hinge -0.030 +0 0.015 –
8 ø 75 –
pin and bearing -0.076 -0.015 0.076
Clearance between front frame +0 -0.041 -0.076 –
9 ø 115 –
and lower hinge bearing -0.015 -0.076 -0.026
Clearance between rear frame +0.089 +0.054 -0.089 –
10 ø 85 –
and bushing +0.059 +0 -0.005
Clearance at seal press-fitting +0.280 +0.054 -0.080 –
11 ø 90 –
portion of lower hinge pin +0.180 +0 -0.126

Height of upper hinge spacer Standard size Tolerance Repair limit

12
(small) 24.5 ±0.1 –
Height of upper hinge spacer
13 64.0 ±0.1 –
(large)

Standard shim thickness of Standard size

14
upper hinge and retainer 2.0
Standard shim thickness of
15 1.0
upper hinge and retainer
Standard shim thickness of
16 1.0 Adjust
lower hinge and retainer

Tightening torque for upper 19.6 ± 2.0 Nm {2.0 ± 0.2 kgm} (When adjusting shim)
17
hinge retainer mounting bolt 98 – 123 Nm {10.0 – 12.5 kgm} (Final value)

Tightening torque for lower 19.6 ± 2.0 Nm {2.0 ± 0.2 kgm} (When adjusting shim)
18
hinge retainer mounting bolt 98 – 123 Nm {10.0 – 12.5 kgm} (Final value)

WA320-5 10-55
 AXLE MOUNTING AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CENTER HINGE PIN

Unit: mm
No. Check item Criteria Remedy

Standard size Tolerance Repair limit

1 Thickness of thrust plate
22 ±0.5 –
+0.3
2 Thickness of thrust washer 5 –
-0.1

Standard Tolerance Standard Clearance Replace

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

10-56 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING PIPING

STEERING PIPING

1. Steering cylinder (right)

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

WA320-5 10-57
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING COLUMN

STEERING COLUMN

1. Steering wheel
2. Steering column
3. Orbit-roll valve
4. Tilt lever
Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between steering size Shaft Hole clearance limit
5 Replace
shaft and column bushing
+0 +0.15 0.05 –
ø 19 0.4
-0.08 +0.05 0.23

10-58 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PRIORITY VALVE

PRIORITY VALVE

P: From steering pump LS: From orbit-roll valve

CF: To orbit-roll valve T: To hydraulic tank
EF: To work equipment control valve

1. Relief valve body 7. Plug

2. Spring seat 8. Valve body
3. Spring 9. Spool
4. Poppet 10. Spring
5. Seat 11. Plug
6. Screen
Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit

Free length Installed Installed Free length Installed

12 Control spring length load load
Replace
63.4 47.6 187 N 63.4 ± 1 187 ± 14.7 N
{19.1 kg} {19.1 ± 1.5 kg}

13 Relief spring 31 26.9 146 N – 146 ± 14.7 N

{14.9 kg} {14.9 ± 1.5 kg}

WA320-5 10-59
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PRIORITY VALVE

Outline Operation
• The priority valve is in the circuit between the
steering pump and the orbit-roll valve. It acts to 1. Steering wheel at neutral
divide the flow of oil from the steering pump and When the engine is stopped, spool (3) is
send it to the orbit-roll valve or oil cooler circuit. pushed fully to the left by the tension of spring
It also sets the oil pressure in the circuit from the (4). The circuit between ports M and N is fully
priority valve to the orbit-roll valve to 20.6 MPa open, while the circuit between ports M and Q is
{210 kg/cm2} to protect the circuit. fully closed.
In this condition, is the engine is started and the
steering pump is rotated, the oil from the pump
goes from the port M to port N, and then enters
port A to the orbit-roll valve.
When this happens, the oil passing through ori-
fice m in spool (3) enters port P. It then com-
presses spring (4), and moves spool (3) to the
right in the direction of the arrow.
This stabilizes the condition so that the circuit
between ports M and Q is almost fully open and
the circuit between ports M and N is almost fully
closed. Therefore, the oil from the pump almost
all flows to the work equipment circuit.

10-60 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PRIORITY VALVE

2. Steering wheel turned to left 3. Steering cylinder at end of stroke

When the steering wheel is turned to the left, an If the operator tries to turn the steering wheel
angle variation is generated between the spool further when the steering cylinder has reached
and sleeve of the orbit-roll valve, and the oil flow the end of its stroke, the circuit from port M
is switched. (For details, see ORBIT-ROLL through port N to port S is kept open and the
VALVE.) pressure rises.
The oil from the pump flows from port M to port When this pressure rises above requirement
N, and enters port A. The degree of opening of pressure relief valve (10) opens and the oil is
the sleeve (port A) and spool (port B) creates a relieved to the hydraulic tank. Because of this
difference between the pressure up to port A flow of oil, a differential pressure is created on
and the pressure beyond port B. Some of the oil both sides of orifice r. Therefore, the balance is
from port B flows to the Girotor, and then goes lost between the load of spring (4) and the pres-
to the front right cylinder. The remaining oil sure up to port A and the pressure beyond port
passes through orifice b, flows to port J, and B. As a result, the pressure up tp the port A
then enters port R. becomes relatively higher.
When this happens, spool (3) stabilizes at a For this reason, the pressure at port P moves
position where the differential pressure between spool (3) even further to the right from the con-
the circuit up to port A and circuit beyond port B dition in Item 2. It stabilizes the condition at a
(pressure of port P - pressure of port R) and the position where the circuit between ports M and
load of the spring (4) are balanced. It adjusts N is almost fully closed, and the circuit between
the degree of opening from port M to ports N ports M and Q is almost fully open.
and Q, and distributes the flow to both circuits.
The ratio of this distributed flow is determined
by the degree of opening of port A and port B,
in other words, the angle variation between the
sleeve and spool of the orbit-roll valve. This
degree the opening is adjusted steplessly by
the amount the steering is turned.

WA320-5 10-61
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ORBIT-ROLL VALVE

ORBIT-ROLL VALVE

P: From steering pump LS: To priority valve

L: To steering cylinder T: To hydraulic tank
R: To steering cylinder

1. Ground 8. Drive shaft

2. Valve body 9. Sleeve
3. Check valve 10. Spool
4. Gerotor 11. Center pin
5. Spacer 12. Centering spring
6. Cover 13. Anti-cavitation valve
7. Spacer 14. Over-load relief valve

10-62 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ORBIT-ROLL VALVE

Outline Structure
• The orbit-roll valve is connected directly to the • Top (A) of spool (3) is connected to the drive
shaft of the steering wheel. It switches the flow shaft of the steering column and further connect-
of oil from the steering pump to the left and right ed to sleeve (5) through center pin (4) (which is
steering cylinders to determine the direction of not in contact with the spool while the steering
travel of the machine. wheel is in neutral) and centering spring (12).
• The orbit-roll valve, broadly speaking, consists • Top (B) of drive shaft (6) is engaged with center
of the following components: rotary type spool pin (4) and combined with sleeve (5) in one
(3) and sleeve (5), which have the function of se- body, and the bottom is engaged with the spline
lecting the direction, and the Girotor set (a com- of rotor (8) of the gerotor set.
bination of rotor (8) and stator (9)), which acts as • Valve body (2) has 5 ports, which are connected
a hydraulic motor during normal steering opera- to the pump circuit, tank circuit, left steering cir-
tions, and as a hand pump (in fact, the operating cuit, right steering circuit, and LS circuit respec-
force of the steering wheel is too high, so it can- tively. The ports on the pump side and tank side
not be operated) when the steering pump or en- are connected by the check valve in the body. If
gine have failed and the supply of oil has the pump or engine fails, the oil can be sucked
stopped. through this check valve directly from the tank
side.

WA320-5 10-63
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ORBIT-ROLL VALVE

Operation

1. Steering wheel at neutral

10-64 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ORBIT-ROLL VALVE

• While the steering wheel is in neutral, spool (3)

and sleeve (5) are fixed at a place where center
pin (4) is set to the center of the oblong hole of
spool (3) by centering spring (12).
At this time, port A of sleeve (5) from the pump,
port E to gerotor, port F of the right steering cir-
cuit, port G of the left steering circuit, and verti-
cal grooves B, C, and D of spool (3) are shut
off.
Orifice b of port J to the priority valve is con-
nected to vertical groove B of spool (3).
Port K of sleeve (5) connects port L of spool (3)
to vertical groove M.
• As a result of above connection and disconnec-
tion of the ports and vertical grooves, the oil
which has been set to the pilot pressure of the
priority valve is drained through port J, orifice b,
vertical grooves M and K, and port L into the hy-
draulic tank.

WA320-5 10-65
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ORBIT-ROLL VALVE

2. Steering wheel turned (turning left)

10-66 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ORBIT-ROLL VALVE

• If the steering wheel is turned to the left, spool 3. Steering wheel stopped
(3) connected by the drive shaft of the steering When the oper ation of steering wheel is
column turns to the left. stopped, the difference in rotation between the
At this time, since spool (3) and sleeve (5) are spool (3) and sleeve (5) is returned to the neu-
connected by centering spring (12), spool (3) tral condition by the reaction of centering spring
compresses centering spring. (12).
Accordingly, an angular displacement is made
between spool (3) and sleeve (5) by the com-
pression of centering spring (12).
Then, port A is connected to vertical groove B
first. Next, vertical groove B is connected to
port E, and then port E is connected to vertical
groove C, and vertical groove C is connected to
port G of the left steering circuit at last.
Orifice b of port J to vertical B and priority valve
is kept connected, but port K of sleeve (5) dis-
connects vertical groove M and port L gradually.
When port A is connected to vertical groove B,
port F of the right steering circuit is connected to
vertical groove D.
• As a result of above connection and disconnec-
tion of the ports and vertical grooves, the oil from
the pump flows through port A to the vertical
groove B, and then flows to port E to rotate the
gerotor. The oil discharged from the gerotor
flows through port E, vertical groove C, and port
G to the head side of the left steering cylinder.
The hydraulic pressure in vertical groove M is
transmitted through orifice b to port J and used
as the pilot pressure of the priority valve.
The oil from the head side of the right steering
cylinder is drained through port F, vertical
groove D, and port H into the hydraulic tank.

WA320-5 10-67
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ORBIT-ROLL VALVE

CONNECTION BETWEEN HAND PUMP AND SLEEVE

• The diagrams above show the connections with Therefore, the amount of oil discharged is
the sleeve ports used to connect the suction and directly proportional to the amount the steering
discharge ports P of the Girotor. wheel is turned.
• If the steering wheel has been turned to the
right, ports a, c, e, g, i, and k are connected by
the vertical grooves in the spool to the pump
side. At the same time, ports b, d, f, h, j, and l
are connected to the head end of the right steer-
ing cylinder in the same way.
In the condition in Fig. 1, ports 1, 2, and 3 are
the discharge ports of the Girotor set.
They are connected to port l, b, and d, so the oil
is sent to the steering cylinder.
Ports 5, 6, and 7 are connected and the oil
flows in from the pump.
If the steering wheel is turned 90°, the condition
changes to the condition shown in Fig. 2. In this
case, ports 2, 3, and 4, are the suction ports,
and are connected to ports k, a, and c. Ports 5,
6, and 7 are the discharge ports, and are con-
nected to ports d, f, and h.
• In this way, the ports acting as the discharge
ports of the Girotor are connected to the ports
going to the steering cylinder, while the ports
acting as the suction ports are connected to the
pump circuit.
• Adjustment of discharge according to amount
steering wheel is turned.
For each 1/7 turn of the steering wheel, the
inside teeth of the Girotor advance one tooth,
and the oil from the pump is discharged in an
amount that matches this movement.

10-68 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ORBIT-ROLL VALVE

Role of centering spring

• Center spring (12) is composed of 4 X-shaped
leaf springs and 2 flat leaf springs and installed
between spool (3) and sleeve (5) as shown in
the figure.
• If the steering wheel is turned, spool (3) com-
presses centering spring (12) and an angular
displacement is made between spool (3) and
sleeve (5).
As a result, the ports of spool (3) and sleeve (5)
are connected and the oil is sent to the steering
cylinder. When the steering wheel stops turn-
ing, the gerotor also stops turning. Then, the oil
is not sent to the steering cylinder and its pres-
sure rises. To prevent this, when the steering
wheel stops turning, it is returned by the reac-
tion force of centering spring (12) toward the
neutral position by the angular displacement of
spool (3) and sleeve (5).

WA320-5 10-69
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CUSHION VALVE

CUSHION VALVE

A: From left swing port of steering cylinder Outline

AS: From left swing port of steering cylinder • When the oil pressure in the steering cylinder
B: From right swing port of steering cylinder rises or rebounds, the cushion valve instantane-
BS: From right swing port of steering cylinder ously lets the high-pressure oil escape to anoth-
er line to prevent a shock.
1. Valve seat
2. Valve body Function
3. Spring • If high-pressure oil flows in port A suddenly, it
4. Poppet compresses spring (3) and pushes poppet (4) of
5. Orifice port A open and flows through the center groove
6. Plug of spool (8), and then pushes poppet (11) of port
7. Spring B open and flows in port B.
8. Spool • At the same time, this high-pressure oil flows
9. Plug through orifice (5) of port A to the pressure
10. Spring chamber of plug (6) and pushes back spool (8)
11. Poppet to the right against the pressure on port B side
and the tension of spring (7). As a result, the oil
flow from port A to port B is stopped.
• This temporary oil flow has a cushioning effect.
Since the cushion valve does not operate after
this, it does not affect the ordinary steering oper-
ation.
• When the pressure changes so slowly that the
cushioning effect is not necessary, spool (8)
stops the oil before poppet (4) is opened, thus
the cushion valve does not work as a cushion.

10-70 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CYLINDER

STEERING CYLINDER

Unit: mm
No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between mounting pin size Clearance limit
1 and bushing at connection of Shaft Hole
frame and cylinder rod
ø 40 -0 +0.180 0.042 – —
-0.025 +0.042 0.205
Clearance between mounting pin -0 +0.180 0.042 –
2 and bushing at connection of ø 40 -0.025 +0.042 0.205 — Replace
frame and cylinder bottom

Width of boss Width of hinge Standard clearance

(a + b)
3 Connection of steering cylinder
and front frame Max. 0.5
50 53
(after adjusting shim)

4 Connection of steering cylinder 50 53 Max. 0.5

and rear frame (after adjusting shim)

WA320-5 10-71
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD STEERING CYLINDER

Unit: mm
No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between piston rod size Clearance limit
1 Shaft Hole
and bushing
-0.025 +0.132 0.031 – Replace pin,
ø 40 -0.064 +0.006 0.196 0.496
bushing
Clearance between piston rod -0 +0.180 0.042 –
2 support shaft and bushing ø 40 -0.025 +0.042 0.205 1.0

Clearance between cylinder bot- -0 +0.180 0.042 –

3 tom support shaft and bushing ø 40 -0.025 +0.042 0.205 1.0

4 Tightening torque of cylinder head 539 ± 53.9 Nm {55 ± 5.5 kgm}

Tightening torque of cylinder pis-

5 ton 785 ± 78.5 kNm {80 ± 8.0 kgm} (Width across flats: 46 mm) Tighten

Tightening torque of nipple plug

6 on cylinder head side 9.8 – 12.74 Nm {1.0 – 1.3 kgm}

10-72 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EMERGENCY STEERING PIPING

EMERGENCY STEERING PIPING

(If equipped)

1. Orbit-roll valve
2. Steering pump
3. HST motor 2
4. Emergency steering valve
5. Pressure switch (For detecting operation of emergency steering)
6. Priority valve
7. Check valve
8. Pressure switch (for detecting drop of steering oil pressure)

WA320-5 10-73
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EMERGENCY STEERING VALVE

EMERGENCY STEERING VALVE

(If equipped)

PP: From steering pump 1. Check valve body

A: To port A of HST motor 2 2. Check valve
B: To port B of HST motor 2 3. Valve body
Y: To orbit-roll valve 4. Pressure reducing valve
S: To hydraulic tank 5. Selector valve
G: To pressure switch

10-74 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EMERGENCY STEERING VALVE

Operation
When engine and steering pump are normal

• While the engine and steering pump are operat-

ing normally, the oil sent from the steering pump
flows into the orbit-roll valve to steer the ma-
chine.
• At this time, the oil from the steering pump flows
in port PP and pushes spool (1) to the left to shut
off the circuit from the HST motor to the orbit-roll
valve.

WA320-5 10-75
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD EMERGENCY STEERING VALVE

When engine or steering pump is abnormal

• If the engine or steering pump has a trouble and

the steering pump does not supply oil sufficiently
to the orbit-roll valve during travel, the discharge
pressure of the steering pump lowers and spool
(1) is pushed back to the right by the reaction
force of spring (2).
• At this time, the oil from the HST motor is set
high by check valves (3) and (4). Then, the oil is
reduced in pressure by pressure reducing valve
(5) to a proper level for the steering circuit and it
flows through spool (1) and port Y to the orbit-roll
valve. As a result, the machine can be steered.
• If the quantity of the oil in the HST circuit be-
comes insufficient because of oil leakage into
the steering circuit, etc., check valves (6) and (7)
add oil to the HST circuit.

a Check valves (3) and (4) work so that the emer-

gency steering system will operate regardless of
the travel direction.

10-76 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE PIPING

BRAKE PIPING

1. Hydraulic tank 8. Accumulator (for rear)

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

WA320-5 10-77
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE

BRAKE VALVE

P1: From HST pump A: To rear brake

T1: To hydraulic tank PB: From accumulator (Front side)
T2: To steering pump (Suction side) B: To front brake
PA: From accumulator (Rear side)

1. Rod 5. Brake valve body (for rear)

2. Inching valve spool 6. Brake valve spool (for front)
3. Inching valve body 7. Brake valve body (for front)
4. Brake valve spool (for rear)
Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between inching size Shaft Hole clearance limit
8
valve spool and body
-0.022 +0.033 0.020 –
ø 22.4 0.096
-0.053 +0 0.086
Clearance between inching -0.022 +0.033 0.020 –
9 ø 22.4 0.096
valve guide and body -0.053 +0 0.086
Clearance between inching -0.050 +0.050 0.050 –
10 ø 12 0.157
valve spool and guide -0.093 +0 0.143
Standard size Repair limit
Replace
Free Installed Installed Free Installed
11 Inching valve control spring length length load length load
24.5 N 20.8 N
34.7 16.7 –
{2.5 kg} {2.1 kg}
113 N 96 N
12 Brake valve control spring 35.6 24.0 {11.5 kg} – {9.8 kg}
19.6 N 16.7 N
13 Inching valve return spring 50.0 49.5 {2.0 kg} – {1.7 kg}
147 N 125 N
14 Brake valve return spring 114.9 52.4 {15.0 kg} – {12.7 kg}

10-78 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE

Outline
• The brake valve is installed under the front of the
operator's seat. If either brake pedal is pressed,
oil flows to the brake piston to operate the brake.
• Both brake pedals are connected mechanically
to each other. If either of them is pressed, the
other moves, too.
• The brake valve has an inching valve in it to con-
trol the control pressure of the HST pump.

Operation
1. When brake pedal is pressed

• If brake pedal (1) is pressed, the pressing force When only either brake operates (When either
is transmitted through rod (2), spool (3), and brake fails)
spring (4) to spool (5). • Even if only either brake operates because of oil
• If spool (5) is pushed to the right, port Ta is leakage, etc. in the front or rear brake system,
closed and the oil from the pump flows through the pressing force of brake pedal (1) moves
the accumulator, port PA, and port A to the rear spools (5) and (6) mechanically to the right.
brake piston to operate the rear brake. Accordingly, the oil from the pump flows nor-
• At the time when spool (5) is pushed to the right, mally to the brake piston of the normal system
spool (6) is also pushed to the right to close port to operate the brake and stop the machine.
Pb. As a result, the oil from the pump flows With this mechanism, safety is heightened.
through the accumulator, port PB, and port B to
the front brake piston to operate the front brake.

WA320-5 10-79
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE

2. When balanced

• If the rear brake piston is filled with oil and the oil • The oil pressure in the rear brake circuit (on port
pressure between ports PA and A rises, the oil A side) is balanced with the pressing force of the
flowing through orifice c of spool (5) into cham- brake pedal. The oil pressure in the front brake
ber E pushes back spool (5) to the left against circuit (on port B side) is balanced with the oil
spring (4) and close ports PA and A from. Since pressure in the rear brake circuit (on port A
port Ta is kept closed at this time, the oil which side).
flowed into the brake piston is held and the If spools (5) and (6) move to the right stroke
brake is kept operated. end, the passes between ports PA and A and
• At the time when spool (5) is pushed to the left, between ports PB and B are fully open and the
the front brake piston is filled with oil and the oil pressure in the rear and front brake circuits is
pressure between ports PB and B rises. As a re- equal to the oil pressure from the pump.
sult, the oil which flowed through orifice d of Accordingly, the operator can adjust the braking
spool (6) into chamber F pushes back spool (6) force with the brake pedal until spool (5) and (6)
to the left by the moving distance of spool (5) to move to the right stroke end.
close ports PB and B. Since port Tb is kept
closed, the oil which flowed into the brake piston
is held and the brake is kept operated.

10-80 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE VALVE

3. When brake pedal is released

• If brake pedal (1) is released, the pedal pressing

force applied to spool (5) is lost.
• Spool (5) is pushed back to the left by the back
pressure of the rear brake piston and reaction
force of spring (7). Consequently, port PA is
closed and the oil in the rear brake piston flows
through ports A and port Ta into the hydraulic
tank and the rear brake is released.
• At the time when spool (5) moves to the left,
spool (6) is also pushed back to the left by the
back pressure of the front brake piston and reac-
tion force of spring (7). Consequently, port PB
is closed and the oil in the front brake piston
flows through ports B and Tb into the hydraulic
tank and the front brake is released.

WA320-5 10-81
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD INCHING VALVE

INCHING VALVE

P1: From port Y of HST pump Outline

T2: To steering pump (Suction side) • The inching valve is built in brake valve (2). It re-
duces the control oil pressure of the HST circuit
1. Brake pedal to reduce the capacity of the HST pump accord-
2. Brake valve ing to stroke (S) of spool (3).
3. Spool
4. Body

10-82 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CHARGE VALVE

CHARGE VALVE

10-84 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CHARGE VALVE

P: From brake and cooling fan pump

T: To hydraulic tank
A: To cooling fan motor
ACC1: To accumulator (Rear side)
ACC2: To accumulator (Front side)
S: Brake operation sensor port
G: Gauge port

1. Valve body
2. Inverse shuttle valve
3. Plunger
4. Unload relief valve
5. Flow control valve
6. Unload valve
7. Relief valve
Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between inverse size Shaft Hole clearance limit
8
shuttle valve spool and body
-0.006 +0.011 0.006 –
ø 12 0.029
-0.014 +0 0.025
Clearance between plunger -0.005 +0.009 0.005 –
9 ø8 0.024
and body -0.012 +0 0.021
Clearance between flow control
-0.006 +0.011 0.006 –
10 valve, unload valve spool and ø 18 0.032
-0.017 +0 0.028
body
Standard size Repair limit
Free Installed Installed Free Installed
Inverse shuttle valve return Replace
11 length length load length load
spring
9.8 N 8.3 N
21.6 18.3 –
{1.0 kg} {0.85 kg}
Unload relief valve return spring 188 N 160 N
12 35.9 30.0 –
(inside) {19.2 kg} {16.3 kg}

13 Unload relief valve return spring 39.8 27.5 137 N – 116 N

(outside) {14.0 kg} {11.8 kg}

14 Flow Control valve return spring 53.7 45.0 89.2 N – 76 N

{9.1 kg} {7.8 kg}

15 Unload valve spool return 51.6 45.0 49 N – 42 N

spring {5.0 kg} {4.3 kg}

16 Check valve return spring 11.5 9.0 4.9 N – 4.2 N

{0.5 kg} {0.43 kg}

Function
• The charge valve keeps the oil pressure from
the pump to the set pressure and stores it in the
accumulator.
• If the oil pressure rises above the set pressure,
the oil from the pump is led to the drain circuit to
reduce the load on the pump.

WA320-5 10-85
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CHARGE VALVE

Operation 2. When oil is supplied to accumulator

1. When oil is not supplied to accumulator 1) Cut-in state
(Cut-out state) • If the accumulator pressure lowers, the
• Plunger (1) is moved by the pressure of the pressure in port E lowers and plunger
accumulator to the left to keep unload relief (1) moves to the right and unload relief
valve (2) pushed open. valve (2) closes the drain circuit.
• The oil in the spring chamber of unload • Accordingly, the oil pressure in port F
valve (3) flows through port F, unload relief and the spring chamber of unload relief
valve (2), and port T into the hydraulic tank. valve (3) rises and unload relief valve
• Since the oil pressure in port F lowers, un- (3) moves to the right.
load valve (3) is moved by the oil pressure in • As a result, ports C and B are connect-
chamber B to the left. ed to each other and the oil from the
• Accordingly, ports C and D are connected to pump flows to port B.
each other and almost all the oil from the • If the oil pressure in port B exceeds the
pump flows through ports P, C, D and A to set pressure of check valve (4), it push-
the cooling fan motor. es check valve (4) open and flows to
port E to start heightening the pressure
in the accumulator. The supply pres-
sure for the accumulator is decided by
the set pressure of check valve (4).
• A set quantity of oil is supplied to the ac-
cumulator, regardless of the engine
speed, and the excessive oil flows
through port A to the cooling fan motor.
• The oil flowing to port E is supplied first
to the accumulator having the lowest
pressure by inverse shuttle valve (5).

10-86 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CHARGE VALVE

2) Cut-out state 3. When input pressure to valve rises above set

• If the pressure in port F reaches the set pressure
pressure (cut-out pressure) of unload • If the oil pressure in chamber B reaches the
relief valve (2), the oil in the spring set pressure of relief valve (6), the oil flowing
chamber of unload valve (3) flows from the pump through port P to chamber B
through port F, unload relief valve (2), pushes relief valve (6) open and flows
and port T to the hydraulic tank. through port T into the hydraulic tank.
• Plunger (1) is moved to the left by the As a result, the maximum pressure in the
pressure of the accumulator to keep un- brake circuit is limited to protect the circuit.
load relief valve (2) pushed open.
• Since the oil pressure in port F lowers,
unload valve (3) is moved by the oil
pressure in chamber B to the left.
• Accordingly, ports C and D are connect-
ed to each other and almost all the oil
from the pump flows through ports P, C,
D and A to the cooling fan motor.

WA320-5 10-87
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR (FOR BRAKE)

ACCUMULATOR (FOR BRAKE)

1. Cylinder
2. Piston

Function
• The accumulator is installed between the charge
valve and brake valve. The space between its
cylinder (1) and free piston (2) is filled with nitro-
gen gas. The brake oil pressure is stored in this
space by utilizing the compressibility of the nitro-
gen gas and used as the pressure source to
drive the brake.

Specifications
Gas used: Nitrogen gas
Amount of gas: 500cc
Charge pressure: 3.43 ± 0.1 MPa {35 ± 1.0 kg/cm2}
(at 20°C)

10-88 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER

SLACK ADJUSTER

A: From brake valve

B: To brake piston

1. Body
2. Check valve
3. Piston
Unit: mm
No. Check item Criteria Remedy

Standard Tolerance Standard Clearance

Clearance between piston and size Shaft Hole clearance limit
4
body
-0.065 +0.052 0.065 –
ø 30 0.163
-0.098 +0 0.150
Clearance between check -0.013 +0.015 0.013 –
5 ø 10 0.048
valve and body -0.028 +0 0.043
Replace
Standard size Repair limit
Free Installed Installed Free Installed
6 Piston return spring length length load length load
11.8 N 9.8 N
87.5 48.2 –
{1.2 kg} {1.0 kg}
53.9 N 46.1 N
7 Check valve return spring 21.7 19.25 {5.5 kg} – {4.7 kg}

10-90 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SLACK ADJUSTER

Function
• The slack adjuster is installed to the brake oil
line from the brake valve to the brake piston and
used to fix the time lag of operation of the brake.

Operation
When brake is applied When brake is released
• The oil from the brake valve flows to port A and • The oil kept between piston (1) and brake piston
moves piston (1) to the right. The oil kept be- pushes back piston (1) to the left. Oil of quantity
tween piston (1) and brake piston drives the equivalent to the moving distance of piston (1) is
brake. returned through port A to the brake valve and
• Since the oil kept between piston (1) and brake drained into the hydraulic tank.
piston drives the brake, the brake piston stroke
is fixed and the time lag of operation of the brake
is reduced.
• If the quantity of the oil between piston (1) and
brake piston becomes insufficient because of
wear of the brake disc, etc., check valve (2) is
pushed open and oil is added.

WA320-5 10-91
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE

BRAKE

1. Differential housing 6. Sun gear shaft

2. Bearing carrier 7. Axle housing
3. Piston 8. Outer ring
4. Spring 9. Discs (x2)
5. Inner ring (x2)
Unit: mm
No. Check item Criteria Remedy

Standard size Tolerance Repair limit

10 Thickness of inner ring
6.5 ± 0.1 6.0

Thickness of brake disc 8.7 ± 0.15 7.9

11 Depth of lining groove 0.8 ± 0.2 0.4

Thickness of lining 1.0 0.8 (Min.) —

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

Standard size Repair limit

13 Spring load Installed height Installed load Installed load

7.6 912 N {93 kg} 730 N {74 kg}

10-92 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BRAKE

Outline
• The brake has a wet-type multiple-disc struc-
ture, and consists of piston (3), inner ring (5),
disc (9), outer ring (8), and spring (4).
• The brake cylinder consists of differential hous-
ing (1) and bearing carrier (2), and piston (3) is
assembled in it.
Inner ring (5) and outer ring (8) are joined to
the spline portion of axle housing (7).
• Disc (9) has a lining stuck to both sides. It is as-
sembled between inner ring (5) and outer ring
(8), and is joined by the spline of sun gear shaft
(6).

Outline
When brake is applied When brake is released
• When the brake pedal is depressed, pressure oil • When the oil pressure is released, piston (2) is
P goes from the hydraulic tank through the returned to its original position by the force of
pump and brake charge valve. It acts on the pis- spring (8), a gap is formed between inner ring
ton inside the brake cylinder and the piston (2) (3) and outer ring (5), and discs (4) become free.
slides. Lattice shape grooves are cut into the lining
Therefore, piston (2) stops the rotation of discs stuck to disc (4), and when disc (4) is rotating,
(4) fitted between inner ring (3) and outer ring oil flows in the grooves and carries out cooling of
(5), and applies the brake to the machine. the lining.

WA320-5 10-93
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE CONTROL

PARKING BRAKE CONTROL

1. Parking brake lever 4. Control cable

2. Lowest switch of parking brake lever 5. Transfer
3. Intermediate switch of parking brake lever 6. Multiple-disc brake lever

Outline
• The mechanical parking brake is built in transfer • If parking brake lever (1) is returned, multiple-
(5). If parking brake lever (1) is operated, multi- disc brake lever (6) connected by control cable
ple-disc brake lever (6) is operated to "apply" or (4) is pushed down and the parking brake is "re-
"release" the parking brake. leased"
• If parking brake lever (1) installed on the opera- • While the parking brake is "applied", the current
tor's seat is pulled, multiple-disc brake lever (6) to the forward-reverse solenoid valve of the HST
connected by control cable (4) is pulled up and pump is shut off and the swash plate of the HST
the parking brake is "applied". pump is kept in neutral.

10-94 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE

PARKING BRAKE

1. Lever 5. Plate
2. Housing 6. Disc
3. Ball 7. Wave spring
4. Piston 8. Output shaft

Unit: mm
No. Check item Criteria Remedy

Standard size Tolerance Repair limit

Thickness of plate
9 2.6 ± 0.06 2.5

Distortion of plate — 0.05 0.1

Replace
Thickness of brake disc 2.2 ± 0.08 2.05
10
Distortion of brake disc — 0.02 0.25

Load on wave spring 1,010 N ± 101N 858 N

11 (Height: 2.2 mm) {103 kg} {± 10.3 kg} {87.6 kg}

Outline
• The parking brake is a wet multiple-disc brake
which mechanically brakes transmission output
shaft (8).
• Lever (1) is connected to the control cable. If the
parking brake lever is pulled, ball (3) between
piston (4) connected to lever (1) and housing (2)
moves on the inclined surface of the piston
groove. As a result, piston (4) presses plates (5)
and discs (6) to brake output shaft (8).

WA320-5 10-95
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING

HYDRAULIC PIPING

10-96 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC PIPING

1. Work equipment control valve Outline

2. Bucket cylinder • The hydraulic system consists of the HST, steer-
3. Hydraulic tank ing, work equipment, brake, cooling fan, and
4. Work equipment PPC valve transfer lubricating circuit. Work equipment cir-
5. Lock valve cuit controls the operation of the lift arm and
6. Oil cooler bucket.
7. Check valve • The oil in hydraulic tank (3) is sent by the work
8. 4-gear pump unit equipment pump of 4-gear pump unit (8) to work
• Steering pump equipment control valve (1). If both spools of the
• Work equipment pump lift arm and bucket of work equipment control
• Brake and cooling fan pump valve (1) are held, the oil flows through the drain
• Transfer lubricating oil pump circuit of work equipment control valve (1) and is
9. Accumulator (for PPC circuit) filtrated by the return filter installed to hydraulic
10. Cut-off valve tank (3) and returns to hydraulic tank (3).
11. Accumulator (for E.C.S.S.) (If equipped) • If the work equipment control lever is operated,
12. Lift cylinder the spool of the lift arm or bucket of work equip-
13. E.C.S.S. valve (If equipped) ment PPC valve (4) operates.
(E.C.S.S.: Electronically Controlled Suspension • The oil from the PPC valve hydraulically oper-
System) ates each spool of work equipment control valve
(1) and flows to lift cylinder (12) or bucket cylin-
der (2) to move the lift arm or bucket.
• The maximum pressure in the hydraulic circuit is
controlled by the relief valve in work equipment
control valve (1). The bucket cylinder circuit has
a safety valve (safety-suction valve) to protect it-
self.
• Accumulator (for PPC circuit) (9) is installed to
the PPC pilot circuit so that the work equipment
can be lowered to the ground even if the engine
stops.
• Hydraulic tank (3) is pressurized, enclosed, and
equipped with a breather which has a relief valve
and which is also used as an oil filler cap. The
breather pressurizes the tank and prevents gen-
eration of negative pressure and cavitation.

WA320-5 10-97
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT LEVER LINKAGE

WORK EQUIPMENT LEVER LINKAGE

2-lever type

1. Lift arm control lever

2. Bucket control lever
3. Wrist rest
4. Lock valve
5. Safety lock lever
6. Work equipment PPC valve
7. Wrist rest height adjustment lever

10-98 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT LEVER LINKAGE

Multi function mono-lever type

(If equipped)

a The following figure shows the vehicle equipped with the attachment control lever.

1. Work equipment control lever

2. Attachment control lever
3. Forward-reverse shifting switch
4. Wrist rest
5. Lock valve
6. Safety lock lever
7. Work equipment PPC valve
8. Attachment PPC valve
9. Wrist rest height adjustment lever

WA320-5 10-99
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK

HYDRAULIC TANK

1. Oil filler cap / Breather Specifications

2. Return filter
Tank capacity (l) 124
3. Hydraulic tank
4. Drain plug Oil quantity inside the tank (l) 89
5. Sight gauge Bypass valve setting pressure 0.2
6. Return filter bypass valve (MPa{kg/cm2}) {2.04}

10-100 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HYDRAULIC TANK

Breather

1. Oil filler cap

2. Case
3. Unlocking knob
4. Sleeve
5. Poppet
6. Filter element

Prevention of negative pressure in tank

• Since the hydraulic tank is pressurized and en-
closed, negative pressure can be generated
when the oil level in the tank lowers. At this time,
sleeve (4) is opened by the pressure difference
from the atmospheric pressure and the atmos-
phere flows in the tank to prevent generation of
negative pressure.
(Set pressure of air intake valve:
3.0 ± 0.3 kPa {0.03 ± 0.003 kg/cm2})

Prevention of rise of pressure in tank

• While the hydraulic circuit is in operation, the
pressure in the hydraulic tank rises when the oil
level in the hydraulic tank rises according to the
operation of the hydraulic cylinders and when
the temperature rises. If the pressure in the tank
rises above the set pressure, poppet (5) oper-
ates to release the pressure from the tank.
(Set pressure of exhaust valve:
0.1 ± 0.015 MPa {1.0 ± 0.15 kg/cm2})

WA320-5 10-101
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 4-GEAR PUMP UNIT

4-GEAR PUMP UNIT

(Steering / Work equipment / Brake and cooling fan / Transfer lubricating oil)
SAR(3)90 + (2)32 + SBR(1)18 + 12

1. Steering pump Outline

2. Work equipment pump • The 4-gear pump unit is installed to the HST
3. Brake and cooling fan pump pump and driven through its shaft to supply hy-
4. Transfer lubricating oil pump draulic oil to the steering, work equipment,
brake, cooling fan, and transfer.

10-102 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 4-GEAR PUMP UNIT

Unit: mm
No. Check item Criteria Remedy

Model Standard clearance Clearance limit

SAR(3)90
5 Side clearance SAR(2)32
0.10 – 0.15 0.19
SBR(1)18
SBR(1)12
SAR(3)90 0.083 – 0.144
Clearance between inside SAR(2)32 0.071 – 0.121
6 diameter of plain bearing and 0.20
SBR(1)18 Replace
outside diameter of gear shaft
0.068 – 0.115
SBR(1)12
Model Standard size Tolerance Repair limit
SAR(3)90 13
+0
SAR(2)32 12
7 Diving depth of pin -0.5
SBR(1)18 10 –

+0.5
SBR(1)12 7
+0
8 Spline rotating torque 13.8 – 28.5 Nm {1.4 – 2.9 kgm}
Discharge Standard Discharge
Speed pressure discharge amount
Model
(rpm) (MPa {kg/ amount limit
Discharge amount cm2} (l/min) (l/min.)
–
– Oil: SAE10W SAR(3)90 129 119
Oil temperature: 45 - 55°C
SAR(2)32 20.6 {210} 91 82
2,500
SBR(1)18 23 21
SBR(1)12 2.9 {30} 27 24

WA320-5 10-103
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR (FOR PPC CIRCUIT)

ACCUMULATOR (FOR PPC CIRCUIT)

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port

Outline
• The accumulator is installed between the HST
charge pump and work equipment PPC valve.
Even if the engine stops with the work equip-
ment raised, the pressure of the compressed ni-
trogen gas in the accumulator sends the pilot oil
pressure to the work equipment control valve to
operate the valve so that the work equipment will
lower by its weight.

Specifications
Gas used: Nitrogen gas
Amount of gas: 300 cc
Charge pressure: 1.18 MPa {12 kg/cm2}) (at 80°C)
Max. using pressure: 6.86 MPa {70 kg/cm2}

10-104 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD LOCK VALVE

LOCK VALVE

1. Lever
2. End cap
3. Ball
4. Seat
5. Body

Outline
• The lock valve is installed between the HST
charge pump and work equipment PPC valve. If
the safety lock lever is set in the LOCK position,
the lock valve operates to shut off the oil in the
PPC circuit so that the work equipment cannot
be operated.

WA320-5 10-105
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD E.C.S.S. VALVE

E.C.S.S. VALVE
(If equipped)
(E.C.S.S.: Electronically Controlled Suspension System)

P: From work equipment pump

T: To hydraulic tank
A: From lift arm cylinder bottom
B: From lift arm cylinder head
SP: To accumulator (for E.C.S.S.)

10-106 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD E.C.S.S. VALVE

1. Main spool
2. Solenoid valve
3. Flow control valve
4. Shuttle valve
5. Charge valve

WA320-5 10-107
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ACCUMULATOR (FOR E.C.S.S.)

ACCUMULATOR (FOR E.C.S.S.)

(If equipped)
1. Valve
2. Top cover
3. Cylinder
4. Free piston

Function
• The accumulator is installed in the lift cylinder
bottom circuit and the space between cylinder
(3) and free piston (4) is filled with compressed
nitrogen gas. The hydraulic pulses generated
on the lift cylinder bottom side during travel are
absorbed by the compressed nitrogen gas to im-
prove the travel performance and operating per-
formance.

Specifications
Gas used: Nitrogen gas
Amount of gas: 3,000 cc
Charge pressure: 2.0 ± 0.1 MPa {20 ± 1.0 kg/cm2}
(at 20°C)

10-108 WA320-5
 HYDRAULIC PIPING OF
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING SYSTEM

HYDRAULIC PIPING OF COOLING SYSTEM

1. Cooling fan motor Outline

2. Brake and cooling fan pump • Cooing fan motor (1) installed to the radiator is
3. Hydraulic tank driven hydraulically by brake and cooling fan
4. Charge valve pump (2).

WA320-5 10-109
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING FAN MOTOR

COOLING FAN MOTOR

P1: From charge valve Specifications

P2: To hydraulic tank
Dr: To hydraulic tank Model MSF-18-16

Fixed displacement swash

1. Port block Type
plate-type piston motor
2. Valve plate
3. Piston Theoretical capacity
16.0
4. Shoe (cc/rev)
5. Thrust plate Rated speed
6. Output shaft 1,700
(rpm)
7. Case
8. Cylinder block Rated capacity
29.3
9. Center spring (l/min)
10. Check valve
11. Check valve spring

10-110 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD COOLING FAN MOTOR

Function
• This hydraulic motor is a swash plate-type axial
piston motor, which converts the pressure of the
hydraulic oil sent from the hydraulic pump into
revolution.

Principle of operation
• The oil sent from the hydraulic port flows through
valve plate (7) into cylinder block (5).
This oil can flow on only one side of the Y-Y line
connecting the top dead center and bottom
dead center of the stroke of piston (4).
• The oil sent to one side of cylinder block (5)
pressed pistons (4) (2 or 3 pieces) and gener-
ates force F1 (F1 kg=P kg/cm2 x x/4 D2 cm2).
• This force is applied to thrust plate (2). Since
thrust plate (2) is fixed to the angle of Eo de-
grees to the output shaft (1), the force is divided
into components F2 and F3.
• The radial components F3 generates torque
against the Y-Y line connecting the top dead
center and bottom dead center (T = F3 x ri).
• The resultant of this torque [T = (F3 x ri)] ro-
tates the cylinder block (5) throught the piston.
• Since the cylinder block (5) is coupled with the
output shaft by means of spline, the output shaft
(1) revolves to transmit the torque.

WA320-5 10-111
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

WORK EQUIPMENT CONTROL VALVE

1. 2-Spool valve

P1: From steering pump P1A:From PPC valve P1 port

T: Drain port (To tank) P1B:From PPC valve P2 port
A1: To bucket cylinder head P2A:From PPC valve P3 port
A2: To lift arm cylinder head P2B:From PPC valve P4 port
B1: To bucket cylinder bottom
B2: To lift arm cylinder bottom

WA320-5 10-113
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

1. Bucket spool
2. Lift arm spool
3. Suction valve
4. Safety-suction valve
5. Check valve
6. Main relief valve

10-114 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit

Free length
Installed Installed Free Installed
X Outside
7 Spool return spring (for bucket) length load length load
diameter

125 N 100 N
54.8 x 34 53.5 —
{12.7 kg} {10.2 kg}
Spool return spring 207.9 N 167 N
8 54.8 x 33.7 52.2 —
(for bucket and lift arm) {21.2 kg} {17 kg}
Spool return spring 255 N 204 N Replace spring
9 30.7 x 32.5 26.5 — If damaged or
(for bucket and lift arm) {26 kg} {20.8 kg}
replaced
Spool return spring 182.4 N 146 N
10 51.9 x 16.9 40 —
(for lift arm) {18.6 kg} {14.9 kg}
Spool return spring 229.5 N 183 N
11 87.6 x 34.7 83.5 —
(for lift arm) {23.4 kg} {18.7 kg}
44.1 N 35.3 N
12 Check valve spring 32.6 x 10.9 24.5 —
{4.5 kg} {3.6 kg}
6.4 N 5.1 N
13 Suction valve spring 64.9 x 12.5 56 —
{0.65 kg} {0.52 kg}

WA320-5 10-115
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

2. 3-spool valve

P1: From steering pump P1A:From attachment PPC valve

T: Drain port (To tank) P1B:From attachment PPC valve
A1: To attachment cylinder head P2A:From PPC valve P1 port
A2: To bucket cylinder head P2B:From PPC valve P3 port
A3: To lift arm cylinder head P3A:From PPC valve P2 port
B1: To attachment cylinder bottom P3B:From PPC valve P4 port
B2: To bucket cylinder bottom
B3: To lift arm cylinder bottom

WA320-5 10-117
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

1. Attachment spool 5. Safety-suction valve

2. Bucket spool 6. Check valve
3. Lift arm spool 7. Main relief valve
4. Suction valve

10-118 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit

Free length
Installed Installed Free Installed
Spool return spring (for bucket X Outside
8 length load length load
and attachment) diameter

125 N 100 N
54.8 x 34 53.5 —
{12.7 kg} {10.2 kg}
Spool return spring (for bucket 207.9 N 167 N
9 54.8 x 33.7 52.2 —
and lift arm) {21.2 kg} {17 kg}
Replace spring
Spool return spring (for bucket 255 N 204 N
10 30.7 x 32.5 26.5 — If damaged or
and lift arm) {26 kg} {20.8 kg}
replaced
182.4 N 146 N
11 Spool return spring (for lift arm) 51.9 x 16.9 40 —
{18.6 kg} {14.9 kg}
229.5 N 183 N
12 Spool return spring (for lift arm) 87.6 x 34.7 83.5 —
{23.4 kg} {18.7 kg}
44.1 N 35.3 N
13 Check valve spring 32.6 x 10.9 24.5 —
{4.5 kg} {3.6 kg}
6.4 N 5.1 N
14 Suction valve spring 64.9 x 12.5 56 —
{0.65 kg} {0.52 kg}

WA320-5 10-119
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

3. Relief valve

• If the oil pressure in ports A and B reaches the

set pressure of pilot poppet spring (4), pilot pop-
pet (3) opens.
• The oil in port A flows through orifice E to ports
B, D, and C.
• As a result, differential pressure is made be-
tween ports A and B.

1. Main valve
2. Poppet seat
3. Pilot poppet
4. Spring
5. Adjustment screw

Function • The differential pressure between ports A and B

• The relief valve is installed at the inlet of the work pushes the main valve open, then the oil in port
equipment control valve and drains the oil into A flows through port C to the drain circuit to let
the hydraulic tank when the oil pressure rises the abnormal pressure escape.
above the set level. In other words, the relief • The set pressure can be changed by increasing
valve limits the pressure in the work equipment or decreasing the tension of pilot poppet spring
circuit to protect the circuit. (4).
• To change the set pressure, loosen the locknut.
Operation Then, tighten or loosen adjustment screw (5) to
• Port A is connected to the pump circuit and port heighten or lower the set pressure.
C is connected to the drain circuit. Oil flows
through the orifice of main valve (1) and fills port
B. Pilot poppet (3) is in contact with (seated on)
poppet seat (2).

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

4. Safety-suction valve

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

Operation

(1) Operation as safety valve

• Ports A and B are connected to the cylinder cir-
cuit and drain circuit respectively.
• The hydraulic oil in port A flows through the hole
of pilot piston (4) to port D. It also flows through
the orifice consisting of main valve (2) and pilot
piston (4) to port C.
• Pilot piston (4) is fixed to the safety valve and the
order of the diameters (areas) of the sections is
d2 > d1 > d3 > d4.

WA320-5 10-121
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

(2) Operation as suction valve 5. Suction valve

• When negative pressure is generated in port A,
the pressure in port D which is connected to port
A becomes negative.
• Since the tank pressure of port B is applied to
port E, the safety valve receives oil pressure "e"
for the differential area between d2 and d2.
• Accordingly, oil pressure "e" is applied in the
opening direction of the valve and oil pressure
"a" is applied in the closing direction of suction
valve (1).
• When the pressure in port A lowers and be-
comes almost negative, it is lower than oil pres-
sure "e".
• When oil pressure "e" > oil pressure "a" + force
of valve spring (5), suction valve (1) opens and
the oil flows through port B to port A, thus the 1. Main poppet
pressure in port A does not become negative. 2. Sleeve
3. Spring

Function
• This valve prevents negative pressure in the cir-
cuit.

Operation
• When negative pressure is generated in port A
(lift arm cylinder head) (When the pressure in
port A is lower than the pressure in tank circuit
port B), main poppet (1) opens because of the
differential area between d1 and d2 and the oil
flows through tank port B to cylinder port A.

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

6. Cut-off valve
a Do not disassemble the cut-off valve. If it is disassembled, its set pressure must be adjusted.

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

P: From work equipment pump 1. Unload valve

C1: To work equipment control valve 2. Check valve
C2: From work equipment control valve 3. Cut-off relief valve
DA: DA port pressure 4. Screen
T1: To tank
T2: To tank

Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit

Free length
Installed Installed Free Installed
X Outside
5 Unload valve spring length load length load Replace spring
diameter
If damaged or
36.95 x 35.3 N 28.4 N replaced
30 —
12.6 {3.6 kg} {2.9 kg}
1.7 N 1.4 N
6 Check valve spring 33 x 13.8 20 —
{0.17 kg} {0.14 kg}

WA320-5 10-125
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

Function
• The cut-off valve is installed between the switch- (1) When work equipment pump pressure is
ing pump and work equipment control valve. It lower than cut-off pressure
sends the oil from the switching pump to the • Similarly to the state where the work equipment
work equipment control valve or drains it to con- valve is held, the oil of the work equipment pump
trol the work equipment speed according to the pushes up check valve (1) and merges with the
working condition. oil from the steering pump and then flows into
the work equipment control valve.
Operating condition of cut-off valve
• While the engine speed is in the low range, the
cut-off valve operates at low pressure.

10-126 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

(2) When work equipment pump pressure is

higher than cut-off pressure
• If the work equipment pump pressure reaches
the cut-off pressure, cut-off valve (2) is opened
by the oil pressure in chamber "a" and then the
oil in chamber "b" of unload valve (3) is drained
through chamber "c" of cut-off valve (2).
• Since the oil in chamber "d" of unload valve (3)
flows through orifices "e" and "f" to chamber "b",
the oil pressure in chamber "d" lowers and un-
load valve (3) opens.
• Accordingly, the oil from the work equipment
pump is drained.

WA320-5 10-127
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

7. Operation of work equipment control valve

(1) Lift arm and bucket spool neutral position

Operation
• The oil flows from the pump to port A and its • The oil from the PPC pump flows in port L of the
maximum pressure is limited by relief valve (1). PPC valve. Since the lift arm and bucket control
• The bypass circuit of bucket spool (2) is opened levers are in the hold positions, however, the oil
to hold the lift arm. As a result, the oil in port A returns through the PPC relief valve to the hy-
flows around the spool into port B. draulic tank.
• Since lift arm spool (3) is in neutral, its bypass
circuit is open. Accordingly, the oil in port B
flows around the spool into the drain circuit and
then returns to the tank.

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

(2) Lift arm spool raise position

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

WA320-5 10-129
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

(3) Lift arm spool lower position

Operation
• If the lift arm control lever is pushed, the oil flows • The oil flows through port E to the cylinder head.
from port L of the PPC valve through port N to • The oil in the cylinder bottom flows through port
port T of work equipment control valve. D into drain port F and then returns to the tank.
• The oil in port S flows to the drain circuit. The oil Accordingly, the lift arm is lowered.
in port T pushes lift arm spool (3) to set it in the
lower position.
• The oil from the pump flows through the bypass
circuit of bucket spool (2) to the bypass circuit of
spool (3).
• Since the bypass circuit is closed by spool (3),
the oil pushes check valve (5) open.

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

(4) Lift arm spool float position

Operation
• If the lift arm control lever is pushed to the float • While the bucket is in contact with the ground, it
position, lift arm spool (3) moves over the lower can move up and down according to the uneven-
position to the float position. ness of the ground.
• The oil from the pump flows through the bypass
circuit of bucket spool (2) to the bypass circuit of
lift arm spool (3).
• The oil in the bypass circuit flows through spool
(3) to the drain circuit and cannot push check
valve (5) open.
• Since raise circuit D and lower circuit E of the lift
arm cylinder are connected to the drain circuit,
the lift arm is lowered by its gravity.

WA320-5 10-131
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

(5) Bucket spool dump position

Operation
• If the bucket control lever is pushed, the oil in • The oil in the bucket cylinder bottom flows
port L of the PPC valve flows through port Q to through port G into drain port F and then returns
port V of the work equipment control valve. to the tank. Accordingly, the bucket is dumped.
• The oil in port R flows to the drain circuit. The oil
in port V sets bucket spool (2) in the dump posi-
tion.
• Since the oil from the pump is stopped by spool
(2), the oil from port A pushes check valve (7)
open.
• The oil from check valve (7) flows through port H
to the bucket cylinder head.

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE

(6) Bucket spool tilt position

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

WA320-5 10-133
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

WORK EQUIPMENT PPC VALVE

2-lever type

P: From HST charge pump

T: To hydraulic tank
P1: To bucket tilt valve
P2: To lift arm LOWER (FLOAT) valve
P3: To lift arm RAISE valve
P4: To bucket DUMP valve

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

1. Spool
2. Metering spring
3. Centering spring
4. Rod
5. Lever
6. Ring
7. Plate
8. Retainer
9. Piston
10. Body

WA320-5 10-135
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

Operation

1. When in neutral
(1) Bucket PPC valve (2) Lift arm PPC valve
• Ports PA1 and PB1 of the bucket control valve • Ports PA2 and PB2 of the lift arm control valve
and ports P1 and P4 of the PPC valve are con- and ports P2 and P3 of the PPC valve are con-
nected through fine control hole f of spool (1) to nected through fine control hole f of spool (1) to
drain chamber D. drain chamber D.

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

2. When in fine control mode

(Neutral o Fine control)

• If rod (4) and piston (9) are pushed by lever (5),

retainer (8) is pushed and spool (1) is also
pushed down through metering spring (2).
• Accordingly, the fine control hole f is disconnect-
ed from drain chamber D and connected to
pump pressure chamber PP almost simultane-
ously. Then, the pilot hydraulic oil of the main
pump flows through fine control hole f and port
P2 to port PA2.
• If the pressure in port P2 rises, spool (1) is
pushed back and fine control hole f is discon-
nected from pump pressure chamber PP and
connected to drain chamber D almost simultane-
ously to release the pressure in port P2.
• Accordingly, spool (1) moves up and down so
that the force of metering spring (2) will be bal-
anced with the pressure in port P2.
• The positional relationship between spool (1)
and body (10) (that fine control hole f is between
drain chamber D and pump pressure chamber
PP) does not change until retainer (8) reaches
spool (1).
• Since metering spring (2) is compressed in pro-
portion to the control lever stroke, the pressure
in port P2 rises in proportion to the control lever
stroke, too.
• Accordingly, the control valve spool moves to a
point at which the pressure in chamber PA2
(that is the same as the pressure in port P2) is
balanced with the force of the control valve spool
return spring.

WA320-5 10-137
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

3. When in fine control mode (When control le- 4. When lever is moved to stroke end
ver is returned)

• If lever (5) is returned a little, spool (1) is pushed • Lever (5) and rod (4) push down piston (9) and
up by the force of centering spring (3) and the retainer (8) pushes down spool (1) to disconnect
pressure in port P2. fine control hole f from drain chamber D and
• Accordingly, fine control hole f is connected to connect it to pump pressure chamber PP.
drain chamber D to release the hydraulic oil • Accordingly, the pilot hydraulic pressure from
through port P2. the main pump flows through fine control hole f
• If the pressure in port P2 lowers too much, spool and port P2 into chamber PA2 to push the con-
(1) is pushed down by metering spring (2) and trol valve spool.
fine control hole f is disconnected from drain • The oil returning from chamber PB2 flows
chamber D and connected to pump pressure through port P3 and fine control hole f' into drain
chamber PP almost simultaneously to supply chamber D.
the pump pressure until the pressure in port P2
rises again to the level equivalent to the lever
position.
• When the control valve spool returns, the oil in
drain chamber D flows in chamber PB2 through
fine control hole f' of the valve which is not mov-
ing and port P3.

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

5. When lift arm is "floated" 6. When "floating" of lift arm is reset

• If rod (4) and piston (9) of port P2 are pushed • If lever (5) is released at the FLOAT position, le-
down further from the LOWER position with le- ver (4') is pushed down to turn the solenoid cur-
ver (5), they are moved to the FLOAT position. rent OFF. Accordingly, the force to keep lever
• Rod (4') on the opposite side is pushed up and a (5) in the FLOAT position is canceled and lever
current flows in the solenoid in body (10), and (5) returns to the neutral position.
then rod (4') is kept pushed up and the lever (5) • When the lift arm is raised or the bucket is tilted,
is kept at the FLOAT position even if it is re- the PPC valve operates similarly to the above.
leased.
• At this time, the control valve is also moved to
the "float" position and kept in that position.

WA320-5 10-139
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

Mono-lever type
a Do not disassemble the cut-off valve. If it is disassembled, its set pressure must be adjusted.

P: From HST charging pump

T: To hydraulic tank
P1: To bucket TILT valve
P2: To bucket DUMP valve
P3: To lift arm RAISE valve
P4: To lift arm LOWER (FLOAT) valve

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

1. Spool 6. Joint
2. Metering spring 7. Plate
3. Centering spring 8. Retainer
4. Rod 9. Piston
5. Nut (for connecting lever) 10. Body

WA320-5 10-141
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

Operation

1. When in NEUTRAL
(1) PPC valve for bucket (2) PPC valve for lift arm
• Ports PA and PB of the bucket control valve and • Ports PA and PB of the lift arm control valve and
ports P1 and P2 of the PPC valve are connected ports P3 and P4 of the PPC valve are connected
through fine control hole f of spool (1) to the through fine control hole f of spool (1) to the
drain chamber D. drain chamber D.

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

2. When in fine control

NEUTRAL o Fine control)

• If rod (7) and piston (13) are pushed by disc (8),

retainer (12) is pushed and spool (1) is also
pushed down through metering spring (2).
• Accordingly, fine control hole f is disconnected
from drain chamber D and connected to pump
pressure chamber PP almost simultaneously,
and then the pilot oil of the main pump flows
from port P1 to port PB.
• If the pressure in port P1 rises, spool (1) is
pushed back and fine control hole f is discon-
nected from pump pressure chamber PP and
connected to drain chamber D almost simultane-
ously to release the pressure in port P1.
• As a result, spool (1) moves up and down to bal-
ance the force of metering spring (2) with the
pressure in port P1.
The positional relationship between spool (1)
and body (14) (where fine control hole f is be-
tween drain chamber D and pump pressure
chamber PP) does not change until retainer (12)
comes in contact with spool (1).
• Since metering spring (2) is compressed in pro-
portion to the stroke of the control lever, the
pressure in port P1 rises in proportion to the
stroke of the control lever.
• Accordingly, the control valve spool moves to a
position at which the pressure in the chamber
PB (equal to the pressure in port P1) is balanced
with the force of the control valve spool return
spring.

WA320-5 10-143
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

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

(When control lever is returned)

• If disc (8) begins to return, the force of centering • If disc (8) and rod (7) push down piston (13) and
spring (3) and the pressure in port P1 push up retainer (12) pushes down spool (1), fine control
spool (1). hole f is disconnected from drain chamber D and
• As a result, fine control hole f is connected to connected to pump pressure chamber PP.
drain chamber D and the oil in port P1 is re- • Accordingly, the pilot oil from the main pump
leased. flows through fine control hole f and port P1 into
• If the pressure in port P1 lowers too much, spool chamber PB and pushes the control valve spool.
(1) is pushed down by metering spring (2) and • The oil returning from chamber PA flows through
fine control hole f is disconnected from drain port P2 and fine control f' into drain chamber D.
chamber D and connected to pump pressure
chamber PP almost simultaneously. Then, the
pump pressure is applied until the pressure in
port P1 is restored to the level corresponding to
the position of the lever.
• When the control valve spool returns, the oil in
drain chamber D flows in through fine control
hole f' of the valve which is not in operation and
then flows through port P2 into chamber PA.

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT PPC VALVE

5. When lift arm is FLOATED 6. When FLOAT state of lift arm is reset

• If rod (7) and piston (13) on the LOWER side of • Disc (8) is returned from the FLOAT position by
port P3 are pushed down by disc (8), ball (15) pushing it down with a force greater than the at-
touches projection a of rod (7) in the middle of tractive force of solenoid (6) and retainer (5).
the stroke (The detent starts to operate). • The FLOAT state also can be reset and the lever
• If rod (7) is pushed in further, ball (15) pushes up can be returned to the neutral position by turning
collar (16) supported on detent spring (17) and off the current in solenoid (6) (demagnetizing the
escapes out to go over projection a of the piston. solenoid).
• At this time, rod (7') on the opposite side is • The lift arm RAISE and bucket TILT operations
pushed up by spring (4) through retainer (5). are carried out similarly to the above.
• If rod (7') is pushed up and the current is flowing
in solenoid (6), retainer (5) is attracted by sole-
noid (6).
• Accordingly, rod (7') is kept pushed up and the
FLOAT state is kept even if the lever is released.
• At the same time, the control valve is also
moved to the FLOAT position and kept at that
position.

WA320-5 10-145
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT PPC VALVE

ATTACHMENT PPC VALVE

T: To the tank P1: To the service valve

P: From the main pump P2: To the service valve

1. Spool 6. Plate
2. Metering spring 7. Retainer
3. Centering spring 8. Body
4. Piston 9. Filter
5. Lever

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT PPC VALVE

Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit

Free length Installed Installed Free Installed
10 Center ring spring x If spring is
length load length load damaged or
Outside diameter
deformed,
41.1 X 15.5 29.0 36.3 N — 30.4 N replace it
{3.70 kg} {3.1 kg}

11 Metering spring 22.7 X 8.10 22.0 16.7 N — 13.3 N

{1.70 kg} {1.36 kg}

WA320-5 10-147
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT PPC VALVE

Operation

1. At the neutral position

• The ports A and B of the control valve and • By the above structure, the spool (1) moves
the ports P1 and P2 of the PPC valve are up and down so that the power of the meter-
being connected to the drain chamber D ing spring (2) and the P1 port pressure may
through the fine control hole of the spool (1). balance.
• Until the retainer (7) hits the spool (1), the
positional relation between the spool (1) and
the body (8) (the fine control hole comes to
the intermediate potion between the drain
chamber D and the pressure chamber of the
pump) does not change.
• Therefore, since the metering spring (2) is
compressed in proportion to the control le-
ver stroke, the pressure at the P1 port also
rises in proportion to the control lever stroke.
• By the above, control valve spool moves to
the position where pressure of the chamber
A (same pressure to P1 port) balances to
the force of control valve spool return spring.

2. At the fine control position

(Neutral o fine control)
• When the piston (4) is pushed by the lever
(5), the retainer (7) is pushed and the spool
(1) also is pushed trough the metering
spring (2) to move to the lower side.
• When the fine control hole f is shut off from
the drain chamber D by the above, it con-
nects to the pressure chamber PP of the
pump almost simultaneously and the pilot
pressure oil of the main pump is led from the
P1 port to the A port through the fine control
hole f.
• When the pressure at the P1 port goes up,
the spool (1) is pushed back and, when the
fine control hole f is shut off from the pres-
sure chamber PP of the pump, it connects to
the drain chamber D almost simultaneously
to release the pressure at the P1 port.

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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ATTACHMENT PPC VALVE

3. At the fine control position (When the control 4. At full stroke

lever is returned) • When the lever (5) pushes down the piston
• When the lever (5) is started to be returned, (4) and when the retainer pushes down the
by the power of the centering spring (3) and spool (1), the fine control hole f is shut off
by the pressure of the P1 port, the spool (1) from the drain chamber D and, then, it con-
is pushed up. By the above, the fine control nects to the pressure chamber PP of the
hole f connects to the drain chamber D to re- pump.
lease the pressurized oil from the P1 port. • Therefore, the pilot pressure oil coming from
• In case the pressure of the P1 port drops ex- the main pump passes through the fine con-
cessively, the spool (1) is pushed down by trol hole f to be led to the A chamber through
the metering spring (2) and the fine control the P1 port to push the control valve spool.
hole f is shut off from the drain chamber D, • The return oil from the B chamber passes
connecting to the drain chamber D almost through the P2 port and the fine control hole
simultaneously to supply the pump pressure f' to flow into the drain chamber D.
PP until the pressure of the P1 port returns
to the pressure corresponding to the lever
position.
• When the control valve spool returns, the oil
in the drain chamber D flows through the
fine control hole f' of the valve which is not
moving to be led to the B chamber through
the P2 port to refill the oil.

WA320-5 10-149
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE

WORK EQUIPMENT LINKAGE

10-150 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE

1. Bucket
2. Tilt lever
3. Bucket cylinder
4. Lift cylinder
5. Lift arm
6. Bucket link
Unit: mm
No. Check item Criteria Remedy

Tolerance
Standard Standard Clearance
Clearance between bushing and size clearance limit
7 Shaft Hole
pin at each end of bucket link
-0.030 +0.174 0.130 –
ø 75 -0.076 +0.100 0.250 1.0

Clearance between bushing and -0.030 +0.174 0.130 –

8 pin of joint of lift arm and bucket ø 75 -0.076 +0.100 0.250 1.0

Clearance between bushing and -0.036 +0.207 0.156 –

9 pin of joint of lift arm and frame ø 85 -0.090 +0.120 0.297 1.0

Clearance between bushing and Replace

10 pin of joint of bucket cylinder bot- ø 95 -0.036 +0.207 0.156 – 1.0
-0.090 +0.120 0.297 (Replace if pin
tom and frame has scuff mark)
Clearance between bushing and
11 pin of joint of bucket cylinder rod ø 95 -0.036 +0.207 0.156 – 1.0
and tilt lever -0.090 +0.120 0.297

Clearance between bushing and -0.036 +0.207 0.156 –

12 pin of joint of tilt lever and lift arm ø 110 -0.090 +0.120 0.297 1.0

Clearance between bushing and

13 pin of joint of lift cylinder rod and ø 85 -0.036 +0.207 0.156 – 1.0
lift arm -0.090 +0.120 0.297

Clearance between bushing and

14 pin of joint of lift cylinder bottom ø 85 -0.036 +0.207 0.156 – 1.0
and frame -0.090 +0.120 0.297

Width of boss Width of hinge

Standard
Standard Standard clearance
15 Joint of bucket cylinder and size Tolerance size Tolerance
frame
+0.8
90 +0 93 ± 1.5 0.7 – 4.5 Replace (Insert
shims on both
16 Joint of lift arm and frame 105 — 109 ± 1.5 2.5 – 5.5 sides so that
clearance will be
1.5 mm or less on
+1.5 each side)
17 Joint of lift arm and bucket 105 — 108 +0 3.0 – 4.5

+2.8 +1.5
18 Joint of bucket link and bucket 104 -0.5 109 +0 2.2 – 7.0

-0
19 Joint of lift cylinder and frame 85 -0.5 89 ± 1.5 2.5 – 6.0

+2.8
20 Joint of tilt lever and bucket link 104 -0.5 109 ± 1.5 0.7 – 7.0
Replace
21 Joint of tilt lever and lift arm 194 ± 0.5 197 ± 0.5 2.0 – 4.0

Joint of bucket cylinder and tilt 0 Replace (Adjust

22 lever 90 -0.5 93 ± 1.5 1.5 – 5.0 clearance on each
side to
23 Joint of lift arm and lift cylinder 85 — 88 ± 1.5 1.5 – 4.5 1.5 mm or less)

WA320-5 10-151
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BUCKET

BUCKET

1. Bucket 4. Bucket tooth (If equipped)

2. Wear plate 5. Adapter (If equipped)
3. Bolt-on cutting edge
Unit: mm
No. Check item Criteria Remedy

Standard size Repair limit

6 Wear of cutting edge (Thickness)
Turn over or
31.8 19 replace
7 Wear of cutting edge (Length) 90 5

8 Wear of bucket tooth 51 21 Replace

Adjust or
9 Clearance of adapter mount Max. 0.5 — replace

10-152 WA320-5
 BUCKET POSITIONER AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM KICK-OUT

BUCKET POSITIONER AND BOOM KICK-OUT

1. Bucket positioner proximity switch 4. Bucket cylinder

2. Boom kick-out proximity switch 5. Lift arm
3. Plate 6. Plate

Unit: mm
No. Check item Criteria Remedy

7 Clearance of bucket positioner 3–5

proximity switch
Adjust
8 Clearance of boom kick-out prox- 3–5
imity switch

10-154 WA320-5
 BUCKET POSITIONER AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM KICK-OUT

OUTLINE

Bucket positioner
• The bucket positioner is driven electrically.
When the bucket is returned to an angle from the
DUMP position toward the TILT position, the
bucket positioner returns the work equipment
(bucket) control lever from the TILT position to
the HOLD position to automatically stop the
bucket at a proper digging angle.
• Plate (3) is bolted to the rod of bucket cylinder
(4). Proximity switch (1) is bolted to the cylinder.
• If the work equipment (bucket) control lever is
moved from the DUMP position to the TILT posi-
tion, the rod of bucket cylinder (4) moves toward
the front of the machine. When plate (3) parts
from proximity switch (1) at a point, proximity
switch (1) operates to return the work equipment
(bucket) control lever to the HOLD position.

Boom kick-out
• The boom kick-out is driven electrically. When
the lift arm is raised to an angle before the max-
imum position, the boom kick-out returns the
work equipment (lift arm) control lever from the
RAISE position to the HOLD position to auto-
matically stop the lift arm at the current position.
• Plate (6) is fixed to lift arm (5). Proximity switch
(2) is fixed to the front frame.
• If the work equipment (lift arm) control lever is
moved from the LOWER position to the RAISE
position, lift arm (5) rises. When plate (6) parts
from proximity switch (2), proximity switch (2)
operates to return the work equipment (lift arm)
control lever to the HOLD position.

WA320-5 10-155
 BUCKET POSITIONER AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM KICK-OUT

OPERATION OF PROXIMITY SWITCH

When bucket is tilted

• While the bucket is dumping more than the set • If the work equipment (bucket) control lever (7)
position of the bucket positioner, plate (2) is over is moved to the TILT position, bucket dump
the sensing face of proximity switch (1), the lamp spool (8) moves up and is held at that position by
of which is lighting up. the coil magnetized by detent solenoid (6). As a
At this time, bucket positioner relay (4) is turned result, work equipment (bucket) control lever (7)
on and a current flows in detent solenoid (6) of is held at TILT position and the bucket tilts.
work equipment PPC valve (5) to magnetize the
coil.

10-156 WA320-5
 BUCKET POSITIONER AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM KICK-OUT

• If the bucket tilts and parts from the set position FUNCTION OF PROXIMITY SWITCH
of the bucket positioner, or if plate (2) parts from
over the sensing face of proximity switch (1), the When object of sensing is over sensing face of
lamp of proximity switch (1) goes off and bucket proximity switch
positioner relay (4) is turned off. Accordingly,
the circuit of detent solenoid (6) of work equip- Lamp of proximity switch ON
ment PPC valve (5) is turned off to demagnetize Bucket positioner relay switch circuit Made
the coil.
Bucket dump spool (8) held at the TILT position Work equipment PPC valve detent
Made
receives the reaction force of spring (9) and solenoid circuit
returns work equipment (bucket) control lever Work equipment PPC valve detent
(7) to the HOLD position. Magnetized
solenoid

When object of sensing is apart from over

sensing face of proximity switch

Lamp of proximity switch OFF

Bucket positioner relay switch circuit Broken

Work equipment PPC valve detent

Broken
solenoid circuit

Work equipment PPC valve detent

Demagnetized
solenoid

WA320-5 10-157
 BUCKET POSITIONER AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM KICK-OUT

When lift arm is raised • If the work equipment (lift arm) control lever (7)
• While the lift arm (3) is lower than the set posi- is moved to the RAISE position, lift arm lower
tion of the boom kick-out, plate (2) is over the spool (8) moves up and is held at that position by
sensing face of proximity switch (1), the lamp of the coil magnetized by detent solenoid (6). As a
which is lighting up. result, work equipment (lift arm) control lever (7)
At this time, boom kick-out relay (4) is turned on is held at RAISE position and the lift arm rises.
and a current flows in detent solenoid (6) of
work equipment PPC valve (5) to magnetize the
coil.

10-158 WA320-5
 BUCKET POSITIONER AND
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD BOOM KICK-OUT

• If the lift arm (3) rises and parts from the set po- FUNCTION OF PROXIMITY SWITCH
sition of the kick-out, or if plate (2) parts from
over the sensing face of proximity switch (1), the When object of sensing is over sensing face of
lamp of proximity switch (1) goes off and boom proximity switch
kick-out relay (4) is turned off. Accordingly, the
circuit of detent solenoid (6) of work equipment Lamp of proximity switch ON
PPC valve (5) is turned off to demagnetize the Boom kick-out relay switch circuit Made
coil.
Lift arm raise spool (8) held at the RAISE posi- Work equipment PPC valve detent
Made
tion receives the reaction force of spring (9) and solenoid circuit
returns work equipment (lift arm) control lever Work equipment PPC valve detent
(7) to the HOLD position. Magnetized
solenoid

When object of sensing is apart from over

sensing face of proximity switch

Lamp of proximity switch OFF

Boom kick-out relay switch circuit Broken

Work equipment PPC valve detent

Broken
solenoid circuit

Work equipment PPC valve detent

Demagnetized
solenoid

WA320-5 10-159
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER

WORK EQUIPMENT CYLINDER

LIFT CYLINDER

BUCKET CYLINDER

Unit: mm
No. Check Item Criteria Remedy

Tolerance
Name of Standard Standard Clearance
cylinder size clearance limit
Clearance between Shaft Hole
1 piston rod and bush- Replace bushing
ing Lift ø 75 -0.030 +0.279 0.095 – 0.655
-0.076 +0.065 0.355

Bucket ø 80 -0.030 +0.258 0.078 – 0.634

-0.076 +0.048 0.334

Lift ø 85 -0.036 +0.350 0.236 – 1.0

Clearance between -0.090 +0.200 0.440
2 piston rod support-
ing pin and bushing Bucket ø 95 -0.036 +0.207 0.156 – 1.0
-0.090 +0.120 0.297 Replace pin and
-0.036 +0.207 0.156 – bushing
Clearance between Lift ø 85 1.0
cylinder bottom sup- -0.090 +0.120 0.297
3
porting pin and bush- -0.036 +0.207 0.156 –
ing Bucket ø 95 1.0
-0.090 +0.120 0.297

Tightening torque of Lift 162 ± 14.5 Nm {16.5 ± 1.5 kgm}

4
cylinder head Bucket 250 ± 24.5 Nm {25.5 ± 2.5 kgm}

Tightening torque of Lift 294 ± 29.4 Nm {30 ± 3.0 kgm}

5 Retighten
cylinder piston Bucket 294 ± 29.4 Nm {30 ± 3.0 kgm}
Tightening torque of Lift 58.9 ± 73.6 Nm {6.0 ± 7.5 kgm}
6 cylinder piston lock
screw Bucket 58.9 ± 73.6 Nm {6.0 ± 7.5 kgm}

10-160 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD AIR CONDITIONER

AIR CONDITIONER
(If equipped)

AIR CONDITIONER PIPING

1. Air outlet duct 8. Compressor

2. Fresh air inlet filter 9. Hot water return piping
3. Fresh air inlet duct 10. Hot water take-out piping
4. Recirculating air filter 11. Refrigerant piping
5. Recirculating / Fresh air selector damper 12. Air conditioner unit
6. Receiver tank 13. Floor duct
7. Condenser

WA320-5 10-161
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

MACHINE MONITORING SYSTEM

Outline
• The machine monitor system uses the sensors • Normal mode indications are those which are
and other devices installed to various parts of usually being made for ordinary use by the ma-
the machine to observe the condition of the ma- chine operators. The description below applies
chine. It processes this information swiftly and to the contents of the main indications.
displays it on the monitor panel to inform the op-
erator of the condition of the machine. 1. Items which are always indicated
• The indications of the machine monitor will be • Meters (Travel speedometer)
made under the normal mode and under the • Gauges (Engine cooling water temperature
service mode. gauge, HST oil temperature gauge and fuel
• The machine monitor has ON/OFF output func- level gauge)
tion of automatic preheating which assists with • Pilot indications
the starting of the engine. • Service meter
• The machine monitor has the relay ON/OFF out-
put function to cut the output to the HST solenoid 2. Items which will be indicated only when some
when the HST controller has a trouble. abnormality occurs
• Cautions
• Action code indications (When the machine
monitor panel mode selector switch (>) is
depressed and released while the action
code is being indicated, the failure code (6
digits) will be indicated.)

3. When the time comes to change the filter or oil,

necessary items for the filter change or oil
change will be indicated on the character dis-
play. (Maintenance monitoring functions)

4. In addition to the above, this system is equipped

with the functions to indicate the travel distance
integrating meter (odometer), to reset the filter/
oil changing time, and to select the language by
use of the character display and the machine
monitor panel mode selector switch which is the
operation switch of the character display.

10-162 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

• This machine monitoring system is equipped • Also, the service mode is equipped with the fol-
with the service mode function to facilitate the lowing functions necessary when replacing the
troubleshooting work for respective controllers machine monitor.
(including the machine monitor itself) on the net-
work. The description below applies to the con- 1. Service meter setting
tents of the main functions. This function is to be used to make setting of the
service meter value being memorized by the
1. Electric fault history machine monitor. However, this setting is valid
This function will indicate the electric fault history only toward the direction to increase the current
data of respective controllers being memorized value.
by the machine monitor. Also, it can be used to
delete the aforementioned data. 2. Travel distance integrating meter value setting
This function is to be used to set the travel dis-
2. Machine fault history tance integrating meter value being memorized
This function will indicate the machine fault his- by the machine monitor. However, this setting is
tory and machine fault history data of respective valid only toward the direction to increase the
controllers being memorized by the machine current value.
monitor. a For "Setting service meter" and "Setting inte-
grated travel distance", ask the manufacturer
3. Real time monitor since they are carried out with the initializing
This function will make real time indications of function.
the inputting data and outputting data being rec- • The machine monitoring system consists of the
ognized by respective controllers on the net- machine monitor proper, buzzer, and switches
work. that are used for inputting data to the machine
monitor proper, sensors, respective controller
4. Maintenance monitor on the network, and relevant switches and sen-
This function is to be used for revisions of the sors.
preset filter and oil changing time. (Revision of
the time for the maintenance monitor operation)

5. Selection of optional items

This function is used to set the machine model,
tier size, and optional equipment.

6. Controller initializing function

This function is being used to effect the settings
of this machine monitor before shipment from
our factory.

WA320-5 10-163
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

Individual circuit diagrams of the machine monitor

Starting and lighting

10-164 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

1. Starting switch Connection table of connector pins of machine mon-

2. Alternator itor
3. Emergency flasher switch
4. Flasher unit Symbol Connector pin No.
5. Turn signal lever a CNL23-3
6. Turn signal lamp (Left)
7. Turn signal lamp (Right) b CNL23-1
8. Head lamp relay
c CNL23-12
9. Lamp switch
10. Dimmer switch d CNL22-11
11. Head lamp (Lo)
e CNL23-17
12. Head lamp (Hi)
13. Clearance lamp, tail lamp relay f CNL21-12
14. Clearance lamp, tail lamp
15. License plate lamp g CNL22-12
16. Working lamp relay h CNL23-9
17. Tachograph lamp (If equipped)

WA320-5 10-165
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

Power supply and network

1. Monitor panel mode selector switch 1 "U" Connection table of connector pins of machine mon-
2. Monitor panel mode selector switch 1 "u" itor
3. Monitor panel mode selector switch 2 "<"
4. Monitor panel mode selector switch 2 ">" Symbol Connector pin No.
5. HST controller a CNL23-11

b CNL21-2

c CNL21-1

d CNL21-4

e CNL21-5

f CNL22-6

g CNL22-2

h CNL21-3

i CNL21-7

j CNL21-15

k CNL23-14

10-166 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

Sensing

1. Alarm buzzer Connection table of connector pins of machine mon-

2. HST filter clogging sensor itor
3. Steering oil pressure sensor
(Machines equipped with emergency steering) Symbol Connector pin No.
4. Emergency steering oil pressure sensor a CNL21-11
(Machines equipped with emergency steering)
5. Coolant level sensor b CNL23-6
6. Brake oil pressure sensor
c CNL22-3
7. Engine oil pressure sensor
8. Parking brake not applied signal d CNL22-5
9. Parking brake indicator signal
e CNL23-8
10. Fuel level sensor
11. HST oil temperature sensor f CNL23-19
12. Coolant temperature sensor (for monitor)
13. Axle oil temperature sensor g CNL23-10

h CNL21-13

i CNL23-18

j CNL23-13

k CNL21-14

l CNL21-16

m CNL21-8

WA320-5 10-167
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

HST safety control

1. Forward-reverse lever Connection table of connector pins of machine mon-

2. HST safety relay itor
3. Motor 1 solenoid valve
4. Clutch solenoid valve Symbol Connector pin No.
5. HST controller a CNL22-8

b CNL22-10

c CNL22-9

d CNL22-6

e CNL22-2

f CNL21-3

g CNL23-15

10-168 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

Autmatic preheating

1. Coolant temperature sensor (for preheating) Connection table of connector pins of machine mon-
2. Automatic preheater relay itor
3. Engine heater relay
4. Ribbon heater Symbol Connector pin No.

a CNL21-6

b CNL22-4

WA320-5 10-169
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITORING SYSTEM

CAN input
Machine monitor HST controller
CAN output

Forward-reverse lever signal HST control

Machine monitor Model selection –– Model selection

HST function selection HST control

Travel speed pulse Travel speedometer

Gear speed signal Indication of 1, 2, 3, or 4

HST controller ––
Error Indication of characters

Input/Output state signal Real-time monitor

10-170 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD MACHINE MONITOR

MACHINE MONITOR
a Monitor lamps 17 and 18 do not operate on this machine.

1. HST oil temperature gauge 16. Axle oil temperature caution lamp
2. HST oil temperature caution lamp 17. Engine oil level caution lamp
3. Engine water temperature gauge 18. Air cleaner clogging caution lamp
4. Engine water temperature caution lamp 19. Maintenance caution lamp
5. Speedometer 20. Radiator water level caution lamp
6. Turn signal pilot lamp (Left) 21. HST oil filter clogging caution lamp
7. Head lamp beam pilot lamp 22. Engine oil pressure caution lamp
8. Turn signal pilot lamp (Right) 23. Battery charge circuit caution lamp
9. Meter indication pilot lamp 24. Character display
10. Fuel level caution lamp 25. Steering oil pressure caution lamp
11. Fuel level gauge (Machines equipped with emergency steering)
12. Centralized warning lamp 26. Emergency steering pilot lamp
13. Parking brake pilot lamp (Machines equipped with emergency steering)
14. Brake oil pressure caution lamp 27. Preheater pilot lamp
15. Parking brake not applied caution lamp 28. Gear speed selector switch position pilot lamp
29. Forward-reverse lever position pilot lamp

10-172 WA320-5
 LIST OF ITEMS DISPLAYED
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ON MONITOR

LIST OF ITEMS DISPLAYED ON MONITOR

Condition for judging running of engine: When running judgment A or B is satisfied, it is judged that the engine
is running.
1. Input is given to alternator terminal R (24 V).
2. Engine oil pressure is normal (Open).
3. Signal of terminal C has been input at least once after IGN_BR, and then it has been turned OFF at least
once.

Judgment of operation
A: After 1 and 2 are established simultaneously, it is judged that the engine is running until IGN_BR is turned
OFF.
B: If 1 and 3 are established simultaneously or 2 and 3 are established simultaneously, it is judged that the
engine is running. If both signals of 1 and 2 are lost, however, it is judged that the engine is stopped even
if IGN_BR is turned ON.

Pri-
Lamp Period of lamp Buzzer Condition for operation Period of buzzer
ority

Warning for dangerous Period: 1,600 msec

w: ON and OFF condition ON: 800 msec
Q: ON – 1
continuously (When error indication OFF: 800 msec
or caution is turned on) (DUTY 50%)

Period: 1,600 msec Caution for wrong oper-

Period: 240 msec
ON: 800 msec ation, etc. (When abnor-
w: Flash A: Intermittent ON 1: 80 msec 2
OFF: 800 msec mal operation is
OFF: 160 msec
(DUTY 50%) performed)

Period: 240 msec Cancellation of calibra-

E: Cancellation
A: Intermittent ON 1: 80 msec tion, etc. (When opera- ON: 1,000 msec (Once) 3
sound
OFF: 160 msec tion is not accepted)

ON: 1,000 msec.

E: Condition is Completion of calibra-
e: Completion OFF: 160 msec.
set sepa- – tion, etc. (When com- 4
sound ON: 1,000 msec (Once)
rately pleted normally)

WA320-5 10-173
 LIST OF ITEMS DISPLAYED
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ON MONITOR

Operation
Engine is stopped Engine is running

Centralized warning

Centralized warning
Individual indication

Individual indication
Indication of failure

Indication of failure
Condition for Indication

Warning buzzer

Warning buzzer
code message

code message
Division No. Item Device Remarks
operation color

When clear-
Backup Bulb for night
– Backup lamp ance lamp is – – – – – – – – Orange
lamp light
ON
km/h or MPH
Indication of
Unit 9 meter LED – Q – – – Q – – Green (Selected by setting
monitor)
Conversion of If there is error in
Pointer: travel speed communication, con-
5 Travel speed – – – – – – – – –
Movement pulse into dition is held until key
travel speed is turned OFF.
Other than
– – – – – – – – –
below
HST oil tem- Pointer: Alarm: Above w
1 perature/HST Movement Q Q B@CRNS w Q Q B@CRNS Red White range: 50 - 110°C
110°C
2 oil tempera- Indicator: Red range: 110 - 135°C
ture caution LED HST oil tem-
perature: – – – DGH1KX – – – DGH1KX –
Above 150°C
Other than
– – – – – – – – –
below
Engine water Alarm: Above –
Pointer: Q – – – Q – – Red
temperature/ 102°C
3 Movement White range: 50 - 102°C
Engine water Alarm: Above w
4 Indicator: Q Q B@BCNS w Q Q B@BCNS Red Red range: 102 - 135°C
temperature 105°C
Gauge/ caution LED
Meter Engine water
temperature: – – – DGE2KX – – – DGE2KX –
Above 150°C
Pointer: Other than – – – – – – – – –
10 Fuel level / Movement below
Fuel level
11 caution Indicator: Above 110z
LED – Q – – – Q – – Red
(Below 5%)
Conversion of
travel speed
Odometer pulse into – – – – – – – – –
travel dis-
tance
24 LCD Operates
when charge
is normal.
Service meter – – – – – – – – –
Corresponds
to clock time
in 1:1.
Other than Lamp is turned ON by
below – – – – – – – – – each controller and
Centralized message is indicated
12 Bulb
warning lamp When error is E E E on character display.
E E E E E Red Lamp is turned ON by
made
caution.
Oil pressure
is normal – – – – – – – – –
(GND) *1: For 30 sec just
Brake oil after key is turned ON
Oil pressure
pressure Q w Q Q and engine is started
14 Bulb is abnormal – – – – Red
(Accumulator (OPEN) (*1)
*2: 30 sec after
oil pressure) engine is started
Oil pressure (after *1)
is abnormal – – – – w Q Q 2G42ZG Red
(OPEN) (*2)
Caution Other than Lamp lights up and
– – – – – – – – –
lamp below warning buzzer
Prevention of
When appli- sounds when engine
omitting to
15 Bulb cation of is stopped and park-
apply parking
parking brake A Q Q – – – – – Red ing brake is released
brake
is omitted (or when key is turned
(24 V) OFF).
Oil tempera-
– – – – – – – – –
ture is normal *3: Oil temperature
Oil tempera- above 120°C is
ture is abnor- w Q Q B@C7NS w Q Q B@C7NS Red detected for continu-
mal (*3) ous 5 seconds or oil
Axle oil tem-
16 Bulb temperature above
perature Brake oil tem- 115°C is detected for
perature: – – – DGR1KX – – – DGR1KX – continuous 5 seconds
Above 150°C and the travel speed
Detection of is above 35 km/h.
error – – – DGR1KB – – – DGR1KB –

10-174 WA320-5
 LIST OF ITEMS DISPLAYED
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ON MONITOR

Operation
Engine is stopped Engine is running

Centralized warning

Centralized warning
Individual indication

Individual indication
Indication of failure

Indication of failure
Condition for Indication

Warning buzzer

Warning buzzer
code message

code message
Division No. Item Device Remarks
operation color

Oil level is – – – – – – – – – If error is detected

normal (GND) when IGN_C signal is
turned ON. Error is
not detected while
engine is running. (If
Engine oil tem-
17 perature Bulb abnormality is
Oil level is detected when key is
low (OPEN) – Q – B@BAZK – – – – Red
turned ON, alarm is
kept turned ON until
normal oil level is
detected.)
Normal
(OPEN) – – – – – – – – – Error is detected only
Clogging of air
18 Bulb while engine is run-
cleaner Clogging ning.
– Q – – – Q – AA1ANX Red
(GND)
Normal – – – – – – – – –
19 Maintenance Bulb 30 h before
– Q – E – Q – E Red
maintenance
Water level is
– – – – – – – – – Error is judged when
Caution Radiator water normal (GND)
lamp 20 Bulb it is detected for 30
level Water level is – Q – B@BCZK – Q – B@BCZK Red sec.
low (OPEN)
Normal
– – – – – – – – – Error is judged when
Clogging of (OPEN)
21 Bulb HST oil temperature
HST oil filter Clogging
– Q – 15BONX – Q – 15BONX Red is above 50°C.
(GND)
Oil pressure
is normal – – – – – – – – –
(OPEN)
Engine oil Oil pressure – Q – – w Q Q B@BAZG Red Error is detected 15
22 Bulb is low (GND) sec after engine is
pressure
When abnor- started.
mality is
– – – DHE4L6 – – – – Red
detected
(OPEN)
Normal volt-
age (24 V) w – Q AB00L6 – – – – Red
Battery charge
23 circuit Bulb
Defective
charge (0 V) – Q – – w Q Q AB00MA Red
When turn
Interlocked with turn
signal lever is
6 Turn signal signal lever. Oper-
turned ON Q Q
Bulb (while key is
– – – – – – Green ates when hazard
8 lamp lamp switch is turned
turned OFF,
ON.
too)
When beam
of head lamp
is turned ON Interlocked with lamp
Beam of head
7 Bulb (When both – Q – – – Q – – Blue switch and dimmer
lamp
head lamp switch.
and beam are
turned ON)
Parking brake Lamp lights up when
is released – – – – – – – – – parking brake is
(OPEN) applied.
Parking Parking brake Operation of forward-
13 Bulb is applied – Q – – – Q – – Red reverse (F-R) lever is
Pilot lamp brake (GND) prohibited and warn-
Prevention of ing buzzer is turned
dragging of A Q Q – A Q Q – Red ON while parking
parking brake brake is applied.
Steering oil Oil pressure
pressure is normal – – – – – – – – –
(OPEN)
(Machines
25 equipped with
Bulb
Oil pressure
emergency – Q – – w Q Q DDS5L6 Red
is low (GND)
steering)
Emergency Oil pressure
– – – – – – – – –
steering is lost (GND)
(Machines
26 equipped with
Bulb Oil pressure
is normal – Q – – – Q – – Green
emergency (OPEN)
steering)

a Monitor lamps 17 and 18 do not operate on this machine.

WA320-5 10-175
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STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ON MONITOR

Operation
Engine is stopped Engine is running

Centralized warning

Centralized warning
Individual indication

Individual indication
Indication of failure

Indication of failure
Condition for Indication

Warning buzzer

Warning buzzer
code message

code message
Division No. Item Device Remarks
operation color

Other than Lamp lights up when

– – – – – – – – –
below automatic preheater
is turned ON.
Automatic Output is turned OFF
27 Bulb When engine when IGN_C signal is
preheating is preheated – Q – – – Q – – Orange turned ON.
(postheated) Postheater is turned
ON after IGN_C sig-
nal is turned OFF.
When F is
Forward- F – Q – – – Q – – Green
selected
reverse When N is
29 N LED selected
– Q – – – Q – – Orange
lever
Pilot lamp When R is
position R – Q – – – Q – – Green
selected
When 1st
1 gear speed is – Q – – – Q – – Green
received Indicator lamp lights
Gear When 2nd up when CAN signal
2 gear speed is – Q – – – Q – – Green is received from HST
speed controller.
received
28 selector LED Indicator lamp does
When 3rd not light up when
switch 3 gear speed is – Q – – – Q – – Green CAN communication
position received is defective (All lamps
When 4th go off).
4 gear speed is – Q – – – Q – – Green
received

10-176 WA320-5
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Service mode functions

1. Outline
1) Electrical equipment system failure history 2) Machine system failure history
This function is used to check the electrical This function is used to check the machine
equipment system failure history of each system failure history of each controller
controller saved in the machine monitor. saved in the machine monitor. For the fail-
For the failure codes displayed in the elec- ure codes displayed in the machine system
trical equipment system failure history, see failure history, see TROUBLESHOOTING.
TROUBLESHOOTING. After each failure The contents of the machine system failure
is repaired and the normal operation is con- history displayed on the character display
firmed, delete the failure history. are as follows.
The contents of the electrical equipment
system failure history displayed on the
character display are as follows.

*1: Displayed alternately every 3 seconds

***: The order in which the subject failure

*1: Displayed alternately every 3 seconds occurred
######: Failure code
***: The order in which the subject failure $$$: Frequency of occurrence of the sub-
occurred ject failure
######: Failure code %%%%%: The service meter value of the
$$$: Frequency of occurrence of the sub- first occurrence of the subject
ject failure failure
%%%%%: The time elapsed since the sub- @@@@@: The service meter value at the
ject failure occurrence for the occurrence of the latest failure
first time (it is determined by The failure code failure of a currently
subtracting the service meter detected failure flashes. Up to several
value of the first occurrence machine system failure codes are saved.
from the current service meter
value)
@@@@@: The time elapsed since occur-
rence of the latest failure (it is
determined by subtracting the
service meter value at the lat-
est occurrence from the current
service meter value)
The failure code failure of a currently
detected failure flashes. Up to 20 failure
codes are saved.

WA320-5 10-177
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3) Real-time monitor Any 2 items can be displayed simultane-

This function is used to check the input and ously by specifying their ID Nos. In this
output signals, etc. recognized by each case, they are displayed on the character
controller on the network. display as shown below.
The contents of the real-time monitor dis-
played on the character display are as fol-
lows.

*1: Displayed alternately every 3 seconds

#####: Specified ID Nos.

*1: Changed after 3 seconds %%%: Data. If a unit is used, it is displayed
on the right of the data.
***: Item name
######: ID No. given to each item
%%%: Data. If a unit is used, it is displayed
on the right of the data.

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4) Maintenance monitor
This function is explained in "Operation
manual, Operation, Character display, Dis-
play of replacement periods of filters and
oils". It is used to change the replacement
periods of the filters and oils.

5) Selection of options
With this function, you can display installa-
tion of an optional device and change the
setting of that device. Use this function
after any optional device is installed or
removed.

6) Initialize
This function is used only in the factory. Do
not use it.

7) Setting of service meter

This function is used to set the service
meter value of a machine when the
m ac hi n e m o n i to r o n th a t m ac hi n e i s
replaced.

8) Setting of odometer
This function is used to set the odometer
value of a machine when the machine mon-
itor on that machine is replaced.

a Since "Setting of service meter" and "Setting of

odometer" are executed with the Initialize func-
tion, ask the manufacturer about them.

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2. Operating method

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Items Related to the Fault History of Electric System

1) Selection of displaying and clearing the fault history of electric system
The fault history is displayed in the order of occurrence with the new fault first.
A current fault is displayed prior to the restored ones.
Pressing the > SW displays the next older fault.
Pressing the < SW displays the next newer fault.
After the oldest fault in memory was displayed, a screen is displayed allowing to select clearing the
entire fault history of electric system of the relevant controller.
Pressing the tSW changes the screen to the [Select displaying abnormalities in electric system]
screen on the first layer.
Pressing the USW changes the screen to the [Clear individually the fault history of electric system] or
[Clear the fault history of electric system] screen.

2) Selection of displaying the fault history of electric system (first layer)

Pressing the > SW changes the screen to the [Select the initializing function] screen.
Pressing the < SW changes the screen to the [Select displaying the fault history of vehicle system]
screen.
Pressing the tSW changes the screen to the ordinary or alert screen.
Pressing the USW changes the screen to the [Display abnormalities in electric system] screen.

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3) Selection of displaying the fault history of electric system and clearing the entire fault history of electric
system (second layer)
A current fault is displayed piror to the restored ones.
Pressing the > SW displays the next older fault.
Pressing the < SW displays the next newer fault.
After the oldest fault in memory was displayed, a screen is displayed allowing to select clearing the
entire fault history of electric system of the relevant controller.
Pressing the tSW changes the screen to the [Select displaying abnormalities in electric system]
screen on the first layer.
Pressing the USW changes the screen to the [Clear individually the fault history of electric system] or
[Clear the fault history of electric system]screen.
* If the history consisted of one fault, pressing the switch does not change the screen to that for all-out
clearing (but change the screen to that for individual clearing).

*1: Displayed alternately every 3 seconds

1.[Display the electrical equipment system failure history] screen

2.[Display the electrical equipment system failure history] screen (When there is not history)
3.[Select clearing entirely the electrical equipment system failure history] screen

***: The order in which the subject failure occurred

######: Unified failure code (6 digits)
$$$: Frequency of occurrence of the subject failure
%%%%%: The time elapsed since the subject failure occurrence for the first time (it is determined by
subtracting the service meter value of the first occurrence from the current service meter
value)
@@@@@: The time elapsed since occurrence of the latest failure (it is determined by subtracting the
service meter value at the latest occurrence from the current service meter value)

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4) Clearing individually the fault history of electric system, and clearing the entire fault history of electric
system (the third layer)
Select YES or NO with the < or > SW.
Cursor (_) blinks on the selected item. Pressing the tSW changes the display as follows, with the his-
tory reset if YES was selected, or not if NO was selected:
a. If No (cancel) was selected, the display returns to the [Display the fault history of electric
system] screen of the relevant fault (i.e., the screen before entering the [Clearing individually
(entirely) the fault history of electric system] screen).
b. If YES (clear ) was selected, the display returns to the [Display the fault history of electric
system] screen of a fault next to the relevant fault. If the fault history to be shown exhausts, the
screen returns to the [Select displaying the fault history of electric system] screen.
By default, the cursor is on NO (no reset) to prevent resetting by error.
A current fault cannot be cleared. If it was selected, a peep sounds for one second to notify that the
operation is cancelled.
If a fault was cleared, peeps sound (on for 0.1 sec. - off for 0.1 sec. - on for0.1 sec.) to notify that the
operation has been accepted.
If the entire history was cleared, it is considered to have been cleared even if it consisted of only one
fault .

*1: Displayed alternately every 3 seconds

1.[Clear individually the electrical equipment system failure history] screen

2.[Clear entirely the electrical equipment system failure history] screen

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Items Related to the Fault History of Machine System

1) Display of the fault history of vehicle system
A current fault is displayed prior to the restored ones.
Pressing the > SW displays the next older fault.
Pressing the < SW displays the next newer fault.
After the oldest fault in memory was displayed, a screen is displayed allowing to select clearing the
entire fault history of electric system of the relevant controller.
Pressing the tSW changes the screen to the [Select displaying abnormalities in machine system]
screen on the first layer.

2) Selection of displaying the fault history of machine system (first layer)

Pressing the > SW changes the screen to the [Select the real-time monitor functions] screen.
Pressing the < SW changes the screen to the [Select displaying the fault history of machine system]
screen.
Pressing the tSW changes the screen to the ordinary or alert screen.
Pressing the USW changes the screen to the [Display abnormalities in electric system] screen.

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3) Display of the fault history of vehicle system (second layer)

The fault history is displayed in the order of occurrence with the newest fault first.
A current fault is displayed prior to the restored ones.
The fault history is displayed in the order of occurrence with the newest fault first.
Pressing the > SW displays the next newer fault.
Pressing the < SW displays the next older fault.
Pressing the tSW changes the screen to the [Select displaying abnormalities in vehicle system]
screen.

*1: Displayed alternately every 3 seconds

1.[Display the machine system failure history] screen

2.[Display the machine system failure history] screen (When there is not history)

***: The order in which the subject failure occurred

######: Unified failure code (6 digits)
$$$: Frequency of occurrence of the subject failure
%%%%%: The service meter value of the first occurrence of the subject failure
@@@@@: The service meter value at the occurrence of the latest failure

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Real-time monitor function

The real-time monitor function displays the information saved in the HST controller and machine monitor mount-
ed on the machine in real time.
This function is used for testing, adjusting, and troubleshooting in the normal display mode or 2-item display
mode for displaying 2 data simultaneously.

1) Selection/Display of real-time monitor item

Pressing the > SW changes the screen in the order of No. 1, No. 2, No. 3 --- Select display of 2 items.
Pressing the < SW changes the screen in the order of Select of display of 2 items, No. 13, No. 12, No.
11 ---.
Pressing the tSW changes the screen to the [Select real-time monitor function] screen.
In [Display of real-time monitor]: Pressing the USW holds the displayed data. Pressing it again
returns the displayed data into the active state.
In [Select display of 2 items]: Pressing the USW changes the screen to the [Select 2 items] screen.

2) Selection of real-time monitor function (first

layer)
Pressing the > SW changes the screen to
the [Select maintenance monitor function]
screen.
Pressing the < SW changes the screen to
the [Select display of machine system fail-
ure history] screen.
Pressing the tSW change the screen to
the normal screen or alarm screen.
Pressing the USW change the screen to
the [Display of real-time monitor] screen.

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3) Display of real-time monitor and selection of display of 2 items (second layer)

Pressing the > SW displays the next data.
Pressing the < SW displays the previous data.
Pressing the tSW changes the screen to the [Select real-time monitor function] screen.

In [Display of real-time monitor]: Pressing the USW holds the displayed data. Pressing it again
returns the displayed data into the active state.
In [Select display of 2 items]: Pressing the USW changes the screen to the [Select 2 items] screen.

*1: Changed after 3 seconds

1.[Display of real-time monitor] screen

2.[Select display of 2 items] screen

***: Real-time monitor item name

$$$$$: ID of item
%%%: Data and unit (SI unit)

4) Selection of 2 items (third layer)

How to input ID
a.When the screen appears, the cursor (_)
is blinking at the highest position of
"00000".
b.Each time the > SW or the < SW is
pressed, the digit changes by 1 between
0 and 9.
c.Select a necessary digit and press the
USW.
d.The cursor moves to the 2nd position. Se-
lect the digits for the all positions by per-
forming steps b. and c. above.
e.After selecting the digit for the lowest posi-
tion, press the USW.
f.If the ID is entered, the screen changes to
the [Display 2 items] screen.
g-1.If you press the tSW before finishing
entering the ID, the cursor moves to the
highest position.
g-2.If you press the tSW while the cursor is
at the highest position, the screen re-
turns to the [Select display of 2 items]
screen.

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5) Display of 2 items (fourth layer)

Pressing the tSW changes the screen to the [Select 2 items] screen.
Pressing the USW holds the displayed data. Pressing it again returns the displayed data into the
active state.

*1: Displayed alternately every 3 seconds

$$$$$: ID of item
%%%%: Data and unit (SI unit)

a The first item and second item are displayed alternately every 3 seconds
a If an item ID that cannot be displayed is selected on the [Select 2 items] screen, the data & unit
display box (%%%) is left blank.

Real-time Monitoring Items

Component Terminal
Item ID Real-time monitoring item Item displayed Display unit Displayed range Remarks
detected No.
All the items are shown A value out of the range
Abridged due to SI unit system so
even if some of them are displayed is shown as
limitation of long as the val-
not equipped depending the lowest (highest)
number of letters. ues have units
on models and options. value in the range.
20200 Monitor ROM No. MONITOR ROM --- --- Monitor ---
40000 Travel speed SPEED 1 km/h 0 – 50 HST L41-13
04202 Fuel level FUEL SENSOR 1% 0 – 100 Monitor L23-13
04101 Engine water temperature COOLANT TEMP 1 °C 24 – 131 Monitor L21-16
Engine water temperature
04103 COOLANT Lo 1 °C -31 – 91 Monitor L21-6
low
30100 HST oil temperature HST TEMP 1 °C 24 – 131 Monitor L21-14
30202 Axle oil temperature BRAKE TEMP 1 °C 24 – 131 Monitor L21-8
HST con-
01005 Engine speed ENG SPEED 1 rpm 0 – 3000 HST L42-4
troller CAN
HST con-
32600 HST oil pressure HST PRESS 0.1 MPa 0.0 – 100.0 HST L41-3
troller CAN
Motor 1 solenoid feed- HST con-
80000 MOTOR SOL 1 mA 0 – 1000 HST L41-6
back current troller CAN
Clutch solenoid feedback HST con-
80100 CLUTCH SOL 1 mA 0 – 1000 HST L41-14
current troller CAN
HST con-
50302 Potentiometer voltage SPEED POT 1% 0 – 100 HST L41-1
troller CAN
HST con-
80200 HST traction force TRACTION --- STD/LIMIT HST L42-3
troller CAN

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(Reference) Inspection with real-time monitor

Example) Measurement of engine speed

Measure the engine speed under the following condition.
Cooling water temperature: Within operating range
HST oil temperature: 45 - 55°C
First, check this condition with the real-time monitor.

Condition Real-time monitor item Component ID

Cooling water temperature COOLANT TEMP Machine monitor 04101

HST oil temperature HST TEMP Machine monitor 30100

After checking the above items with the real-time monitor, check the engine speed.

Condition Real-time monitor item Component ID

Engine speed ENG SPEED HST controller 01005

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Maintenance functions

1) Selection/Display of maintenance monitor item

Pressing the > SW changes the screen in the order of No. 1, No. 2, No. 3 ---.
Pressing the < SW changes the screen in the order of No. 13, No. 12, No. 11 ---.
Pressing the tSW changes the screen to the [Select maintenance monitor function] screen.
Pressing the USW changes the screen to the [Change maintenance interval time].

2) Selection of display of maintenance monitor function (first layer)

Pressing the > SW changes the screen to the [Select OPT function] screen.
Pressing the < SW changes the screen to the [Select real-time monitor function] screen.
Pressing the tSW change the screen to the normal screen or alarm screen.
Pressing the USW change the screen to the [Select maintenance monitor item] screen.

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3) Selection of maintenance monitor (second layer)

The contents of this display are the same as those of the maintenance monitor of the function opened
to the operator. Maintenance caution lamp does not light up, however.
Pressing the tSW change the screen to the [Select maintenance monitor function] screen.
Pressing the USW change the screen to the [Change maintenance monitor interval time] screen.

*1: Displayed alternately every 3 seconds

1.[Select maintenance item] screen

2.Example) When the data is HST oil filter

##: ID No. of each maintenance item

***: Each maintenance item

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4) Change of maintenance interval time (third layer)

The maintenance interval time can be set freely to 0 - 9999 h.
If you press the tSW, the time is not changed but the screen changes to the [Select maintenance
item] screen.
At this time, the operation cancel sound (1-second peep) is heard.

How to input interval

a.When the screen appears, the cursor (_) is blinking at the highest position.
b.Each time the > SW or the < SW is pressed, the digit changes by 1 between 0 and 9.
c.Select a necessary digit and press the USW.
d.The cursor moves to the 2nd position. Select the digits for the all positions by performing steps (b.)
and (c.) above.
e.After selecting the digit for the lowest position, press the USW.
f-1.If the input interval time is acceptable, the screen changes to the check screen.
f-2.If the input interval time is not acceptable, the time does not change but the screen changes to the
[Select maintenance item] screen. At this time, the operation cancel sound (1-second peep) is
heard.
g.If you have input a wrong value, press the tSW to return to the [Select maintenance item] screen and
repeat the above steps from the first.

*1: Changed after 6 seconds

##: ID No. of each maintenance item

***: Each maintenance item
%%%%: Current interval time (4 digits)
If there is not a digit in a position of the interval time, input "0". Example: "0012"

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5) Check of change of maintenance interval time (fourth layer)

Select YES or NO with the < or > SW. The cursor (_) blinks on the selected item. Pressing the tSW
returns the screen to the [Select maintenance item] screen with the change done if YES was selected,
or not if NO was selected.
By default, the cursor is on NO (the change not done) to prevent resetting by error.
When the change of the set time is finished, the operation acceptance peeps (on for 0.1 sec o off for
0.1 sec o on for 0.1 sec) are heard.

*1: Displayed alternately every 3 seconds

##: ID No. of each maintenance item

%%%%: Interval time (4 digits) to be changed

The maintenance interval time is set as shown in the following table, when shipped.

Item Replacement interval time (h) Displayed item name ID No.

Engine oil 500 ENG OIL 01

Engine oil filter 500 ENG FILT 02

Fuel filter 500 FUEL FILT 03

Transfer oil 1,000 TRANSF OIL 25

HST oil filter 1,000 HST FILT 26

Hydraulic oil filter 2,000 HYD FILT 04

Hydraulic oil 2,000 HYD OIL 10

Axle oil 2,000 AXLE OIL 15

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Setting required when optional device is installed

When any of the following optional devices is added or replaced, adjust the sensors, etc. to the initial values with
the machine monitor.

Added or replaced optional device Adjustment item

Tire size, machine monitor Model selection, tire size selection, tire deviation selection

Function of selecting optional device

1) Selection and display of optional item
Pressing the > SW or < SW changes the selected optional items in order.
Pressing the tSW changes the screen to the [Select function of selecting optional device]
In [Model selection item]: Pressing the USW changes the screen to the [Select model] screen.
In [Select each optional device]: Pressing the USW updates the items of each optional device.

2) Selection of function of selecting optional

device (fourth layer)
Pressing the > SW changes the screen to
the [Select initializing function] screen.
Pressing the < SW changes the screen to
the [Select maintenance monitor function]
screen
Pressing the tSW changes the screen to
the normal screen or alarm screen.
Pressing the USW changes the screen to
the [Model selection item] screen.

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3) Model selection item and selection of optional device (second layer)

Pressing the > SW or < SW changes the selected optional items in order.
Pressing the tSW changes the screen to the [Select function of selecting optional device]
In [Model selection item]: Pressing the USW changes the screen to the [Select model] screen.
In [Select each optional device]: Pressing the USW updates the items of each optional device.

*1: Changed after 3 seconds

1.[Model selection item] screen

2.[Select tire deviation] screen

Selection of tire deviation

Pressing the USW selects deviation from the standard tire between -12% and +12% (at intervals of 2%). (@@
is the deviation selected when shipped.)
(+00/+02/+04/+06/+08/+10/+12/-02/-04/-06/-08/-10/-12)
When selection is finished, the operation acceptance peeps (on for 0.1 sec o off for 0.1 sec o on for 0.1 sec)
are heard.
Pressing the tSW changes the screen to the [Select function of selecting optional device]

4) Selection of model (third layer)

Pressing the >SW or <SW selects a model.
(100/150/200/250/320)
Pressing the tSW changes the screen to the [Model selection item] screen.
If you press the USW to finish selection, the operation acceptance peeps (on for 0.1 sec o off for 0.1
sec o on for 0.1 sec) are heard and the screen changes to the [Select tire size] screen.

a Select "320" for this machine.

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5) Selection of tire size (fourth layer)

Pressing the > SW or < SW selects a tire size.
(13.0/14.0/15.5/16.9/17.5/18.4/20.5)
If you press the USW to finish selection, the operation acceptance peeps (on for 0.1 sec o off for 0.1
sec o on for 0.1 sec) are heard and the screen changes to the [Model selection item] screen.

a Since "320" was selected on the "Select model" screen, "17.5" or "20.5" can be selected. (Other tire sizes
are not displayed.)

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AMP040-16P [CN-L21]
Pin No. Specification I/O Type of use Signal name WA320-5 Remarks
SW for operating
1 D_IN (NSW +24V) I D/I+24V Service SW t SW input machine monitor
SW for operating
2 D_IN (+24V) I D/I+24V Service SW U SW input machine monitor
3 GND I GND CAN shield GND
SW for operating
4 D_IN (GND) I D/IGND Increment SW < SW input
machine monitor
SW for operating
5 D_IN (GND) I D/IGND Decrement SW > SW input machine monitor
Engine water temperature Engine water temperature
6 A_IN I A/I sensor (For automatic pre- sensor (For automatic pre-
heating) heating)
7 GND I GND Sensor GND GND
Brake oil temperature sen- Brake oil temperature sen-
8 A_IN I A/I
sor sor
9 N.C. – – --- ---
10 N.C. – – --- ---
D_OUT Buzzer Buzzer
11 (+24 V, sink: 200 mA) O D/O sink
(Machine monitor) (Machine monitor)
Lamp switch Lamp switch
12 D_IN (+24V) I D/I+24V
(Clearance lamp) (Clearance lamp)
Parking brake omission pre- Parking brake omission pre-
13 D_IN (NSW +24V) I D/I+24V
vention vention
14 A_IN I A/I HST oil temperature sensor HST oil temperature sensor
15 GND I GND GND GND
Engine water temperature Engine water temperature
16 A_IN I A/I
sensor sensor

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AMP040-12P [CN-L22]
Pin No. Specification I/O Type of use Signal name WA320-5 Remarks
1 N.C. – – --- ---
Machine monitor – HST con-
2 CAN- I/O CAN CAN-
troller
3 D_IN (GND) I D/IGND Emergency steering operation Emergency steering operation (If equipped)
D_OUT
4 O D/O sink Automatic preheater relay Automatic preheater relay
(+24 V, sink: 200 mA)
5 D_IN (GND) I D/IGND Emergency steering normal Emergency steering normal (If equipped)

6 CAN+ I/O CAN Machine monitor – HST con- CAN+

troller
7 N.C. – – --- ---
8 D_IN (+24V) I D/I+24V Direction R Direction R
9 D_IN (+24V) I D/I+24V Direction N Direction N
10 D_IN (+24V) I D/I+24V Direction F Direction F
11 D_IN (+24V) I D/I+24V Turn signal lamp left Turn signal lamp left
12 D_IN (GND) I D/IGND Dimmer switch Dimmer switch

AMP040-20P [CN-L23]
Pin No. Specification I/O Type of use Signal name WA320-5 Remarks
1 D_IN (NSW+24V) I D/I+24V IGN BR IGN BR
2 N.C. – – --- ---
3 D_IN (+24V) I D/I+24V IGN C IGN C
4 N.C. – – --- ---
5 N.C. – – --- ---
6 D_IN (GND) I D/IGND HST filter clogging HST filter clogging
7 D_IN (GND) I D/IGND (Air cleaner clogging) ---
8 D_IN (GND) I D/IGND Engine water level Engine water level
9 D_IN (+24V) I D/I+24V Lamp switch (Head lamp) Lamp switch (Head lamp)
10 D_IN (GND) I D/IGND Engine oil pressure Engine oil pressure

11 NSW power supply I Power supply NSW power supply (+24 V) NSW power supply (+24 V)
(+24 V) +24 V
12 D_IN (GND) I D/IGND Alternator R Alternator R
13 A_IN I A_I Fuel level sensor Fuel level sensor
14 GND I GND GND GND
D_OUT
15 O D/O sink HST solenoid cut-out relay HST solenoid cut-out relay
(+24 V, sink: 200 mA)
16 N.C. – – --- ---
17 D_IN (+24V) I D/I+24V Turn signal lamp right Turn signal lamp right
18 D_IN (+24V) I D/I+24V Parking brake Parking brake
19 D_IN (GND) I D/IGND Brake oil pressure Brake oil pressure
20 D_IN (GND) I D/IGND (Engine oil level) ---

10-198 WA320-5
 ELECTRICAL SYSTEM (HST
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROLLER SYSTEM)

ELECTRICAL SYSTEM (HST CONTROLLER SYSTEM)

System diagram

WA320-5 10-199
 ELECTRICAL SYSTEM (HST
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROLLER SYSTEM)

Control function
1. Speed changing function
The HST controller calculates the maximum speed matched to the selected gear speed and controls the
HST according to the gear speed signal and travel speed adjustment signal.

1. HST controller a. CNL41-10: Travel speed control dial power sup-

2. Gear speed selector switch ply (+5 V)
3. Travel speed control dial b. CNL41-1: Travel speed control potentiometer
4. Shift control relay signal
5. Traction control switch c. CNL41-2: Travel speed control dial GND
d. CNL42-12: Gear speed signal
e. CNL42-3: Traction control signal
Travel speed
Travel speed Traction con- HST motor 1 HST motor 2
Selected gear Traction Clutch sole- control signal
range trol switch solenoid solenoid
speed control noid output input voltage
(km/h) signal output output
(V)
0 – 13
–
(Set with
1st (Normally Unlimited ON MAX – MID MAX. fixed 1.0 – 4.0
travel speed
OFF)
control signal)
Standard
Unlimited
(OFF)
2nd 0 – 13 ON MAX – MID MAX. fixed 1.0 – 4.0
Limited
Limited
(ON)
Standard
Unlimited
(OFF)
3rd 0 – 18 ON,OFF MAX – 0 MAX. fixed 0
Limited
Limited
(ON)
Standard
Unlimited
(OFF) MAX. fixed -
4th 0 – 38 ON,OFF MAX – 0 0
Limited Variable
Limited
(ON)
Note: The travel speed range shown above is for the tire size of 20.5-25.
2. Traction control function
The HST controller can limit the output torque
according to the traction control signals when
the selected gear speed is 2nd - 4th.

10-200 WA320-5
 ELECTRICAL SYSTEM (HST
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROLLER SYSTEM)

3. Travel speed control function (Variable shift control system)

If the gear speed selector switch is set to the 1st position, the maximum speed can be limited to 4 - 13 km/
h with the travel speed control signal.

4. HST motor 1 overrun prevention function

While the machine is traveling at high speed with the gear in the 3rd or 4th position, if the gear is shifted to
the 1st or 2nd position, the clutch is engaged at high speed and HST motor 1 speed exceeds the allowable
limit.
To prevent HST motor 1 from overrunning in this case, the HST controller prohibits shifting the gear from
3rd or 4th position to the 1st or 2nd position while the travel speed is above 10 km/h.
If the gear cannot be shifted, the action code (E00) is displayed on the machine monitor and the alarm
buzzer is turned ON.
The error condition is reset when the travel speed lowers below 9 km/h or the gear speed selector switch is
set in a gear speed position at which the gear can be shifted.

Gear shifting operation Action after gear shifting

Travel speed at
Switch position Switch position Actual gear speed Display of action
gear shifting Remarks
before gear shifting after gear shifting after gear shifting code
(km/h)
2nd 2nd Gear can be
1st 0– 3rd 3rd Not displayed shifted regardless
4th 4th of travel speed.

1st 1st Gear can be

2nd 0– 3rd 3rd Not displayed shifted regardless
4th 4th of travel speed.

1st 1st
0 – 10 2nd 2nd Not displayed Gear can be
4th 4th shifted to 1st or
3rd 2nd only when
1st 3rd travel speed is
Displayed (E00)
10 – 2nd 3rd below 9 km/h.
4th 4th Not displayed
1st 1st
0 –10 2nd 2nd Not displayed Gear can be
3rd 3rd shifted to 1st or
4th 2nd only when
1st 3rd travel speed is
Displayed (E00)
10 – 2nd 3rd below 9 km/h.
3rd 3rd Not displayed

Note: The travel speed range shown above is for the tire size of 20.5-25.

WA320-5 10-201
 ELECTRICAL SYSTEM (HST
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD CONTROLLER SYSTEM)

5. Travel speed limiting function

When the machine travels down a slope at high speed, the axle speed and engine speed exceed the
allowable limit, and the travel speed exceeds the allowable limit consequently.
To limit the travel speed in this case, the HST controller limits the output of HST motor 2 while the travel
speed is above 40 km/h.
If the travel speed is limited, the action code (E00) is displayed on the machine monitor and the alarm
buzzer is turned ON.
The error condition is reset when the travel speed lowers below 39.5 km/h.

10-202 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD HST CONTROLLER

HST CONTROLLER

Input and output signals

AMP 1-963217-1-16P [CN-L41]

Pin No. Signal name Input/Output signal Pin No. Signal name Input/Output signal
Travel speed control potentiome- 9 NC –
1 Input
ter signal Travel speed adjustment potenti-
10 Output
Travel speed potentiometer ometer (+5 V)
2 –
GND 11 NC –
3 HST pressure sensor signal Input 12 HST pressure sensor (+5 V) Output
4 HST pressure sensor GND – 13 Travel speed signal A (Pulse) Input
5 HST motor 2 solenoid Output 14 Clutch solenoid Output
6 HST motor 1 solenoid Output 15 NC –
7 Power supply (+24 V) Input 16 GND –
8 Power supply (+24 V) Input

AMP 2-963217-1-16P [CN-L42]

Pin No. Signal name Input/Output signal
Pin No. Signal name Input/Output signal 9 NC –
1 NC – 10 NC –
2 Checker H Input and output 11 Engine speed sensor GND –
3 Traction control signal Input 12 Gear speed signal Input
4 Engine speed signal Input 13 NC –
Travel speed signal B (Revolv- 14 Checker D Input and output
5 Input
ing direction)
15 Checker B Input and output
6 NC –
16 CAN-H Input and output
7 Checker C Input and output
8 CAN-L Input and output

WA320-5 10-203
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE START CIRCUIT

ENGINE START CIRCUIT

a For details of the directional lever relay, see Electrical circuit diagram.

1. Battery Function
2. Battery relay 1. The neutral safety circuit is employed to secure
3. Starting switch the safety when the engine is started.
4. Directional lever • While the forward-reverse selector switch
5. Neutral safety relay drive switch is OFF, the engine does not
6. Starting motor safety relay start if the forward-reverse lever is not in the
7. Starting motor N (Neutral) position.
8. Alternator
9. Fuel cut-out solenoid
10. Fuel solenoid pull relay
11. Fuel cut-out solenoid timer
12. Machine monitor
13. Short connector
14. Directional lever relay

10-204 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE START CIRCUIT

Operation
1. When starting switch is ON 3. When starting switch is turned to START posi-
• If the starting switch is turned ON, terminals tion
B and BR of the starting switch are closed • If the starting switch is turned to the START
and the current flows from the battery position, terminals B and C of the starting
through the starting switch and battery relay switch are closed and the current flows from
coil to the ground and the contacts are short connector terminal 7 through terminal
closed. As a result, the power is supplied to 8 and neutral safety relay terminals 3 and 5
each circuit of the machine. to starting motor safety relay terminal S, and
At this time, if the signal from terminal ACC then the contacts are closed to start the
of the starting switch flows in the timer starting motor and engine.
relay, the relay contacts are closed for 3 • If the directional lever is not in the N (Neu-
seconds and the current flows into the coil tral) position, the neutral safety relay does
on the pull side of the fuel cut-out solenoid. not operate and the engine does not start.
The current from terminal ACC of the start-
ing switch flows into the coil on the hold
side of the fuel cut-out solenoid to hold the
solenoid so that the fuel will be supplied
even after the coil on the pull side is ener-
gized. The engine is now ready to start.

2. Neutral safety circuit

• If the directional lever is set in the N (Neu-
tral) position, the current flows from contact
N of the forward-reverse lever to the multi-
function selector relay circuit. At this time,
multi-function selector relay circuit supplies
a current as the N signal to the neutral safety
relay coil to connect neutral safety relay ter-
minals 3 and 5.

WA320-5 10-205
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD ENGINE STOP CIRCUIT

ENGINE STOP CIRCUIT

a For details of the directional lever relay circuit, see Electrical circuit diagram.
Operation
1. Battery • The current from ACC terminal of starting switch
2. Battery relay to hold side coil of fuel cut solenoid is cutoff
3. Starting switch when starting is turned off. Fuel supply to engine
4. Directional lever is shut off.
5. Neutral safety relay When the fuel supply is stopped, the engine re-
6. Starting motor safety relay duces its speed and stops. Then, the power
7. Starting motor generation of the alternator stops to shut off volt-
8. Alternator age supply from the terminal L of the alternator.
9. Fuel cut-out solenoid In addition, the current from the terminal BR of
10. Fuel solenoid pull relay starting switch is shut off. Consequently, the
11. Fuel cut-out solenoid timer battery relay contact opens to shut down the
12. Machine monitor power supplied to every circuit of the machine.
13. Short connector
14. Directional lever relay

10-206 WA320-5
 PREHEATING CIRCUIT (AUTOMATIC
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PREHEATING SYSTEM)

PREHEATING CIRCUIT (AUTOMATIC PREHEATING SYSTEM)

1. Battery Operation
2. Battery relay • When the starting switch is turned ON, the ma-
3. Starting switch chine monitor is started up. At this time, if the
4. Automatic preheating relay coolant temperature is 0°C or less, the machine
5. Engine heater relay monitor makes to contact the coil of the preheat-
6. Ribbon heater ing relay to the earth and the preheating relay
7. Machine monitor operates to let the engine heater relay operate to
8. Coolant temperature sensor (For preheating) start preheating by the electric intake air heater.
• The operating time of the preheating process is
Outline as shown below
• The automatic preheating system is being in-
stalled to improve the engine starting capability
in cold weather areas. This system is capable
of shortening the preheating time and, at the
same time, it is capable of making automatic set-
ting of the preheating time matching the current
coolant temperature, by merely turning the start-
ing switch.
• When the starting switch is turned ON, the pre-
heating pilot lamp on the machine monitor lights
and the electric intake air heater starts preheat-
ing the intake air.
As for the preheating time, the coolant tempera-
ture is detected by the coolant temperature sen-
sor and the controller being built into the
machine monitor carries out the preheating time
setting.
• While the pilot lamp is lighting, preheating is in
progress and keep the starting switch at the ON
state. If the starting switch is turned to the
START position, the preheating process is can-
celled.

WA320-5 10-207
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE CIRCUIT

PARKING BRAKE CIRCUIT

a For details of the directional lever relay circuit, see Electrical circuit diagram.

1. Parking brake lever intermediate switch 13. Directional lever

2. Parking brake lever bottom switch 14. Directional lever relay
3. Parking brake relay 15. Forward relay
4. Parking brake selector connector (CNL20) 16. Reverse relay
5. Parking brake selector connector (CNL18) 17. Neutral safety relay
6. Parking brake pilot lamp relay 18. HST pump forward solenoid valve
7. Parking brake drag prevention relay 19. HST pump reverse solenoid valve
8. Machine monitor 20. HST motor 1 solenoid valve
9. Alarm buzzer 21. Clutch solenoid valve
10. HST controller power hold relay 22. HST motor 2 solenoid valve
11. HST controller 23. HST motor forward-reverse selector solenoid
12. HST safety relay valve

10-208 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE CIRCUIT

Operation

1. When parking brake lever is returned (ON o OFF)

Position of starting switch OFF ON

State of engine Stopped Running

Position of parking brake

Lock Mid-Free Free Lock Mid-Free Free Lock Mid-Free Free
lever

Intermediate switch (1) Open Close Open Close Open Close

Bottom switch (2) Open Close Open Close Open Close

Parking brake reminder ON ON

caution lamp OFF (Reset) (Oper- OFF (Reset) (Oper- OFF (Reset)
(Alarm buzzer) ated) ated)

Parking brake pilot lamp OFF ON OFF ON OFF

1) When parking brake lever is in Lock posi- • The parking brake pilot lamp goes off re-
tion gardless of the state of the parking
• When the parking brake is applied, both brake. Parking brake reminder caution
intermediate switch (1) and bottom lamp lights up and the alarm buzzer
switch (2) are open. sounds only when the engine is
• The parking brake pilot lamp lights up stopped.
only while the starting switch is in the • Then, the HST controller power hold re-
ON position and goes off regardless of lay operates and the current flows in the
the state of the parking brake reminder HST controller to hold the operation of
caution lamp. the motor solenoid and clutch solenoid
• The parking brake is applied. and prevent the machine from moving
down on a slope, etc.
2) When parking brake lever is moved from • The parking brake is released.
Lock position to Mid position
• If the parking brake lever is returned a
little, intermediate switch (1) is closed
but the contacts of the parking brake re-
lay are kept open.
• The parking brake pilot lamp and park-
ing brake reminder caution lamp oper-
ate as in step 1).
• The parking brake is kept applied.

3) When parking brake is set in Free position

• If the parking brake lever is returned to
the end, bottom switch (2) is closed.
• At this time, the coil flows in the coil of
the parking brake relay to close the con-
tacts, and then the parking brake pilot
lamp relay operates.
• Since the current flows in the coil of the
parking brake drag prevention relay, the
forward-reverse solenoid circuit is
closed and the machine can travel for-
ward or in reverse and the parking brake
reminder caution signal is input to the
machine monitor.

WA320-5 10-209
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD PARKING BRAKE CIRCUIT

2. When parking brake lever is pulled (OFF o ON)

Position of starting switch OFF ON

State of engine Stopped Running

Position of parking brake

Free Free-Mid Lock Free Free-Mid Lock Free Free-Mid Lock
lever

Intermediate switch (1) Close Open Close Open Close Open

Bottom switch (2) Close Open Close Open Close Open

Parking brake reminder

OFF OFF
caution lamp ON (Operated) ON (Operated) OFF (Reset)
(Reset) (Reset)
(Alarm buzzer)

Parking brake pilot lamp OFF OFF ON OFF ON

1) When parking brake is set in Free position

• When the parking brake is released, • Since the current to the coil of the park-
both intermediate switch (1) and bottom ing brake drag prevention relay is cut
switch (2) are closed. out, the forward-reverse solenoid circuit
• The parking brake pilot lamp goes off re- is opened. Accordingly, the machine
gardless of the state of the parking does not move forward or in reverse
brake. Parking brake reminder caution even if the forward-reverse lever or the
lamp lights up and the alarm buzzer forward-reverse selector switch is oper-
sounds only when the engine is ated.
stopped. • The parking brake pilot lamp lights up
• Then, the HST controller power hold re- only while the starting switch is in the
lay operates and the current flows in the ON position and goes off regardless of
HST controller to hold the operation of the state of the parking brake reminder
the motor solenoid and clutch solenoid caution lamp.
and prevent the machine from moving • The parking brake is applied.
down on a slope, etc.
• The parking brake is released.

2) When parking brake lever is moved from

Free position to Mid position
• If the parking brake lever is pulled a lit-
tle, bottom switch (2) is opened but the
contacts of the parking brake relay are
kept closed.
• The parking brake pilot lamp and park-
ing brake reminder caution lamp oper-
ate as in step 1).
• The parking brake is kept released.

3) When parking brake lever is in Lock posi-

tion
• If the parking brake lever is pulled to the
end, intermediate switch (1) is opened.
• At this time, the current to the coil of the
parking brake relay is cut out and the
contacts are opened and the parking
brake indicator relay is turned OFF.

10-210 WA320-5
 ELECTRONICALLY CONTROLLED
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SUSPENSION SYSTEM

ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM

Electronically Controlled Suspension System (Abbreviation: ECSS)
(If equipped)

1. ECSS controller
2. ECSS relay
3. ECSS switch
4. ECSS solenoid
5. Speed sensor

Function
• The controller controls the ECSS solenoid valve automatically to turn the accumulator charged with high-
pressure gas ON and OFF to damp the vertical movement of the work equipment and reduce the jolts of the
machine during high-speed travel. Consequently, the operator comfort is improved, the material spills less,
and the working efficiency is increased.

System operation table

Travel speed
ECSS switch ECSS solenoid output State of ECSS
(km/h)
OFF 0 – MAX OFF OFF
0–6 OFF OFF
Turn system ON
6 – MAX ON ON
ON
MAX – 5 ON ON
Turn system OFF
5–0 OFF OFF

Note: The travel speed range shown above is for the tire size of 20.5-25.

WA320-5 10-211
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS

SENSORS
Engine speed sensor

1. Wire 4. Housing
2. Magnet 5. Connector
3. Terminal

Function
• The engine speed sensor is installed to the ring
gear of the flywheel housing. As the gear re-
volves, the engine speed sensor generates a
pulse voltage.

Speed sensor

1. Connector 3. O-ring
2. Sensor 4. Bolt

Function
• The speed sensor is installed to the transfer
case. As the gear revolves, the speed sensor
generates a pulse voltage and a revolving direc-
tion signal (Counterclockwise: ON).

10-212 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS

Engine oil pressure sensor

1. Plug 4. Diaphragm
2. Contact ring 5. Spring
3. Contact 6. Terminal
Function
• This sensor is mounted to the engine block. The
diaphragm detects oil pressure, and when it
reaches below the specified value, the switch is
turned ON.

Fuel level sensor

1. Connector 3. Arm
2. Variable resistor 4. Froat
Function
• This sensor is mounted to the side surface of the
fuel tank. The float moves vertically depending
on the remaining quantity of the fuel.
The movement of the float operates the variable
resistor through the arm and sends a signal to
the machine monitor to indicate the remaining
quantity of the fuel.

WA320-5 10-213
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS

Coolant temperature sensor (For monitor)

HST oil temperature sensor

1. Connector
2. Plug
3. Thermistor

Function
• The coolant temperature sensor (for monitor) is
installed to the engine cylinder block and the
HST oil temperature sensor is installed to the hy-
draulic piping of motor 2. They generate ther-
mistor resistance change signals as
temperature change signals.

Coolant temperature sensor (For preheating)

1. Connector
2. Plug
3. Thermistor

Function
• The coolant temperature sensor (for preheating)
is installed to the engine coolant piping. It gen-
erates thermistor resistance change signals as
temperature change signals.

10-214 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS

Axle oil temperature sensor

1. Connector
2. Plug
3. Thermistor

Function
• The axle oil temperature sensor is installed to
the front axle. It generates thermistor resistance
change signals as temperature change signals.

HST oil pressure sensor

Oil puressure sensor for load meter (Load meter specification)

1. Sensor
2. Lead wires
3. Connector

Function
• The HST oil pressure sensor is installed to the • The oil pressure sensors for the load meter are
solenoid block of motor 2. It measures the oil installed on the bottom and rod sides of the lift
pressure in the HST circuit and generates sig- cylinder. They measure the oil pressure in the
nals of that pressure. cylinder and generates signals.

WA320-5 10-215
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS

Steering oil pressure sensor

(Machines equipped emergency steering: If equipped)

Emergency steering oil pressure sensor

(Machines equipped emergency steering: If equipped)

1. Retainer 5. Case
2. Piston 6. Switch
3. Body 7. Connector
4. Push rod

Function
• The steering oil pressure sensor is installed to
the block of priority valve port P. It measures the
oil pressure in the steering circuit and generates
signals of that pressure.
• The emergency steering oil pressure sensor is
installed to the emergency steering valve. It
measures the oil pressure in the emergency
steering circuit and generates signals of that
pressure.

HST filter clogging sensor

1. Terminal
2. Plug

Function
• The HST filter clogging sensor is installed to the
HST filter. It senses the oil pressures before and
after the filter. If the difference between the
measured pressures exceeds the set level, the
switch is turned ON.

10-216 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS

Coolant level sensor

1. Float 3. Connector
2. Sensor 4. Sub-tank

Function
• This sensor is mounted to the sub-tank in the
bulkhead. The float lowers to turn off the switch
when the coolant level reaches below the spec-
ified level.

WA320-5 10-217
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS

Engine oil level sensor

1. Connector 3. Float
2. Bracket 4. Switch

Function
• The engine oil level sensor is installed on the
side of the oil pan. If the oil level lowers below
the set level, the float lowers and the switch is
turned OFF.
Air cleaner clogging sensor

1. Indicator 3. Adapter
2. Spring 4. Connector

Function
• The air cleaner clogging sensor is installed to pressure (negative pressure), the air cleaner
the outlet of the air cleaner. If the air cleaner is clogging sensor sends a signal to the machine
clogged and the pressure lowers to the set monitor.

10-218 WA320-5
STRUCTURE, FUNCTION AND MAINTENANCE STANDARD SENSORS

Lift arm angle sensor

(load meter specification) (if equipped)

1. Shaft 4. Rotor
2. Housing 5. Connector
3. Bearing

Function
• The lift arm angle sensor is installed to the front
frame. If the lift arm angle changes, the shaft of
the lift arm angle sensor receives sliding resist-
ance and senses the change of the lift arm angle
through the link installed on the lift arm side.

WA320-5 10-219
OTHERS

90 OTHERS

Hydraulic circuit diagram .............................................................................................................................. 90-3

Electrical circuit diagram 1/4 (1/4) ................................................................................................................. 90-5
Electrical circuit diagram 1/4 (2/4) ................................................................................................................. 90-7
Electrical circuit diagram 1/4 (3/4) ................................................................................................................. 90-9
Electrical circuit diagram 1/4 (4/4) ............................................................................................................... 90-11
Electrical circuit diagram 2/4........................................................................................................................ 90-13
Electrical circuit diagram 3/4........................................................................................................................ 90-15
Electrical circuit diagram 4/4........................................................................................................................ 90-17

WA320-5 90-1
HYDRAULIC CIRCUIT DIAGRAM

WA320-5 90-3
ELECTRICAL CIRCUIT DIAGRAM 1/4 (1/4)

WA320-5 90-5
ELECTRICAL CIRCUIT DIAGRAM 1/4 (2/4)

WA320-5 90-7
ELECTRICAL CIRCUIT DIAGRAM 1/4 (3/4)

WA320-5 90-9
ELECTRICAL CIRCUIT DIAGRAM 1/4 (4/4)

WA320-5 90-11
ELECTRICAL CIRCUIT DIAGRAM 2/4

WA320-5 90-13
ELECTRICAL CIRCUIT DIAGRAM 3/4

WA320-5 90-15
ELECTRICAL CIRCUIT DIAGRAM 4/4

WA320-5 90-17